Friction and Wear of Ceramics: Principles and Case Studies

About the Authors Foreword by Dr. Sanak Mishra Foreword by Prof. Koji Kato Preface Section I: Fundamentals of Ceramics Chapter 1: Introduction: Ceramics and Tribology 1.1 Introduction 1.2 Classification of engineering materials 1.3 Engineering ceramics 1.4 Structural ceramics: typical properties and tribological applications 1.5 Structure of the book 1.6 Closure References Chapter 2: Processing of bulk ceramics and coatings 2.1 Introduction 2.2 Conventional processing of ceramics 2.2.1 Sintering mechanism 2.2.2 Conventional processing of ceramics 2.2.2.1 Powder processing and Compaction 2.2.2.2 Pressureless sintering 2.2.3 Advanced processing of ceramics 2.2.3.1 Hot pressing 2.2.3.2 Microwave sintering 2.2.3.3. Spark plasma sintering 2.3 Thermal spray based coating deposition 2.3.1. Basics of thermal spray deposition 2.3.1.1 Plasma spray deposition 2.3.1.1.2 Flame spray deposition 2.3.1.3 Wire arc spray deposition 2.3.1.4 High-velocity-oxy-fuel (HVOF) spray deposition 2.3.1.5 Detonation sprayed coatings (DSC) 2.3.2 Bond strength of thermal sprayed coatings 2.3.2.1 Bond mechanism 2.3.2.2 Test methods 2.3.3 Coating structure 2.3.3.1 Particle and substrate material properties 2.3.3.2 Particle temperature and velocity 2.3.4 Case study: WC-Co coating 2.4 Closure References Chapter 3: Conventional and advanced machining processes 3.1 Introduction 3.2 Conventional machining 3.3. Advanced machining processes 3.3.1 Electrodischarge machining (EDM) 3.3.1.1 Working principle 3.3.1.2 EDM process variables 3.3.1.3 EDM parameters 3.3.1.4 Surface analysis 3.3.1.5 EDM of ceramic-based composites 3.4 Closure References Chapter 4: Mechanical properties of ceramics 4.1 Defining stress and strain 4.2 Comparison of tensile behavior 4.3 Brittle fracture of ceramics 4.4. Cracking in Brittle Materials 4.5 Experimental assessment of mechanical properties 4.5.1 Hardness 4.5.2 Compressive strength 4. 5.3 Flexural Strength 4.5.4 Tensile strength 4.5.5 Elastic modulus 4.5.6 Fracture toughness 4.5.6.1 Notched beam tests 4.5.6.2 Indentation microfracture method 4.5.7 Practical guidelines for the for reliable measurements 4.6 Closure References Section II: Fundamentals of Tribology Chapter 5: Contact surface characteristics 5.1 Nature and roughness of contact surfaces 5.2 Surface roughness measurement 5.2.1 Stylus method 5.2.2 Atomoc force microscopy 5.2.3 Optical interferometry 5.2.4 Laser surface profilometry 5.2.5. Scanning electron microscopy 5.3 Bearing area curve and cumulative distribution function 5.4 Nominal vs. real contact area 5.5 Hertzian contact stress 5.6 Closure References Chapter 6: Friction and interface temperatures 6.1 Theory of friction 6.1.1. Friction laws and mechanisms 6.2 Types of friction 6.2.1 Static and kinetic friction 6.2.2 Slip-stick friction 6.2.3 Rolling friction 6.3 Friction of engineering material classes 6.4 Frictional heating and temperature at the interface 6. 4. 1 Heating due to friction 6. 4. 2 Understanding the temperature in the contact: the bulk and flash temperatures 6.5 Analytical models to predict the temperatures in the contact 6.6 Implications of important contact temperature models 6.6.1. Archard model 6.6.2. Kong-Ashby model 6.6 Closure References Chapter 7: Wear of ceramics and lubrication 7.1 Introduction 7.2. Testing methods and quantification of wear of materials 7.3 Classification of wear mechanisms 7.3.1 Tribomechanical wear 7.3.1.1 Adhesive wear 7.3.1.2 Abrasive wear 7.3.1.3 Fatigue wear 7.3.1.4 Fretting wear 7.3.1.5 Erosive wear 7.3.2 Tribochemical wear 7.3.2.1. Oxidative wear 7.4 Lubrication 7.4.1 Regimes of lubrication and the Stribeck curve 7.4.2 Influence of lubricant composition, contact pressure and temperature on lubrication 7.5 Closure References Section III: Sliding Wear of Ceramics Chapter 8: Case Study: Sliding wear of SiC ceramics 8.1 Introduction 8.2. Materials and experiments 8.3 Friction and wear behavior SiC ceramics sintered with small amount of yttria additive 8.4 Influence of mechanical properties on sliding wear of SiC ceramics 8.5. Wear mechanisms 8.6 Closure References Chapter 9: Case study: Counterbody and temperature dependent sliding wear of SiC-WC Ceramics 9.1 Introduction 9.2. Microstructure and mechanical characteristics of SiC-WC composites 9.3. Influence of counterbody and WC content 9.3.1. Friction and wear behavior 9.3.2. Mechanisms of material removal 9.3.3. Friction and wear of SiC-WC composites: system-dependent properties 9.3.4 Wear mechanisms as function of counterbody and WC content 9.4. Reciprocated sliding wear behavior of SiC-WC composites 9.4.1. Frictional and wear behavior 9.4.2. Critical analysis of wear mechanisms 9.4.2.1.Debris analysis 9.4.2.2. Effect of temperature 9.4.2.3. Effect of test configuration on wear behavior 9.5. Sub-surface investigation of worn SiC-WC composites 9.5.1. Sub-surface damages and corresponding inferences 9.5.2 Cross-sectional microstructural analysis and interfacial characteristics 9.5.3. Sub-surface plastic deformation: 9.6. Closure: Chapter 10: Sliding wear of zirconia-toughened alumina 10.1 Introduction 10.2 Mechanical properties of ZTA 10.3 Sliding wear properties of ZTA 10.4 Correlating cracking mediated wear with theoretical analysis 10.5 Closure Chapter 11: Case study: Abrasive wear of detonation sprayed WC-12Co coatings 11.1 Introduction 11.2 Coatings and abrasive wear 11.3. Abrasive wear results 11.4 Surface and sub-surface damage mechanisms 11.5 Closure References Chapter 12: Case study: Solid-lubricant interaction and friction at lubricated contacts 12.1 Introduction 12.2 Materials and sliding wear experiments 12.3 Wetting and spreading properties 12.4 Surface energies of different class of materials 12.5 Wetting evaluation of engineering surfaces 12.6 Effect of wetting on EHL friction 12.7 Correlation between spreading parameter and friction 12.8 Closure References Section IV: Erosive Wear of Ceramics Chapter 13: Case Study: Erosive wear of SiC-WC composites 13.1 Introduction 13.2 Materials and erosion tests 13.3 Influence of type of erodent on erosion behaviour 13.4 Influence of impingement angle and WC content on erosion behavior 13.5 Correlating erosion behaviour with microstructural characteristics 13.6 Correlating erosion behaviour with mechanical properties 13.7 Erosion behaviour at high temperature 13.8 Closure References Chapter 14: Case Study: Thermo-erosive behavior of ZrB2-SiC composites 14.1 Introduction 14.2 High temperature erosion tests and computational modeling 14.3 Computational modeling of thermo-erosive behaviour 14.4 High temperature erosion test results 14.5 Transient thermal studies using Finite Element analysis 14.6 Coupled thermo-structural analysis 14.7 Thermo-erosive behavior 14.8 Closure References Chapter 15: Case Study: Erosive wear of WC-Co coating 15.1 Introduction 15.2 Materials and erosion experiments 15.3 Erosion wear mechanisms (surface damage) 15.4 Erosion wear mechanisms (sub-surface damage) 15.5 Correlating wear mechanism with erodent and coating properties 15.6 Closure References Section V: Machining induced wear of cermets Chapter 16: Crater wear of TiCN cermets in conventional machining 16.1 Introduction 16.2 TiCN cermets and machining conditions 16.3 Wear mechanisms of TiCN-WC-Ni cermets 16.4 Machining with TiCN-WC-TaC-Ni-Co cermet tools 16.5 Correlating cermet composition, microstructure and wear during machining 16.6 Closure References Chapter 17: Wear of TiCN-based cermets in electrodischarge machining 17.1 Introduction 17.2 Materials and EDM tests 17.3 Wear of TiCN-cermets during EDM 17.4 Mechanisms of material removal during EDM 17.5 Closure References Section VI: Future scope Chapter 18: Perspective 18.1 Innovation cycle for wear resistant materials 18.2 in situ diagnosis of tribological interactions 18.3 High temperature wear testing 18.4 Modeling and simulation in tribology 18.5 Tribomaterialomics- a new concept 18.6 Education and mentoring of next generation researchers References Appendix: Appraisal A. I Multiple choice questions A. II Select the appropriate combination A. III Fill in the blanks with the most appropriate response A. IV Mention the appropriate material/equipment in the blank A. V Identify whether the following statements are True/False: A. VI Short review questions and descriptive questions A. VII Analytical questions A. VIII Model answers