Vol. 24 No. 4 2022 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. We sincerely happy to announce that Journal “Obrabotka Metallov” (“Metal Working and Material Science”), ISSN 1994-6309 / E-ISSN 2541-819X is selected for coverage in Clarivate Analytics (formerly Thomson Reuters) products and services started from July 10, 2017. Beginning with No. 1 (74) 2017, this publication will be indexed and abstracted in: Emerging Sources Citation Index. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Affairs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Gerasenko, Director, Scientifi c and Production company “Mashservispribor”, Novosibirsk; Sergey V. Kirsanov, D.Sc. (Engineering), Professor, National Research Tomsk Polytechnic University, Tomsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Evgeniy A. Kudryashov, D.Sc. (Engineering), Professor, Southwest State University, Kursk; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, Institute of Strength Physics and Materials Science, Russian Academy of Sciences (Siberian Branch), Tomsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 24 No. 4 2022 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Dyuryagin A.A., Ardashev D.V. A study of the relationship between cutting force and machined surface roughness with the feed per tooth when milling EuTroLoy 16604 material produced by the DMD method...................... 6 Ulakhanov N.S., Tikhonov A.G., Mishigdorzhiyn U.L., Ivancivsky V.V., Vakhrushev N.V. The features of residual stresses investigation in the hardened surface layer of die steels after diffusion boroaluminizing............... 18 Rubtsov V.E., Panfi lov A.O., Knyazhev E.O., Nikolaeva A.V., Cheremnov A.M., Gusarova A.V., Beloborodov V.A., Chumaevskii A.V., Ivanov A.N. Development of plasma cutting technique for C1220 copper, AA2024 aluminum alloy, and Ti-1,5Al-1,0Mn titanium alloy using a plasma torch with reverse polarity................ 33 Amirov A.I., Moskvichev E.N., Ivanov A.N., Chumaevskii A.V, Beloborodov V.A. Formation features of a welding joint of alloy Ti-5Al-3Mo-1V by the friction stir welding using heat-resistant tool from ZhS6 alloy....... 53 EQUIPMENT. INSTRUMENTS Ardashev D.V., Zhukov A.S. Investigation of the relationship between the cutting ability of the tool and the acoustic signal parameters during profi le grinding..................................................................................................... 64 Bataev D. K-S., Goitemirov R. U., Bataeva P. D. Studies of wear resistance and antifriction properties of metalpolymer pairs operating in a sea water simulator........................................................................................................ 84 Zakovorotny V.L., Gvindjiliya V.E., Fesenko E.O. Application of the synergistic concept in determining the CNC program for turning............................................................................................................................................ 98 MATERIAL SCIENCE Sokolov R.A., Novikov V.F., Kovenskij I.M., Muratov K.R., Venediktov A.N., Chaugarova L.Z. The effect of heat treatment on the formation of MnS compound in low-carbon structural steel 09Mn2Si................................ 113 Burkov А.А., Krutikova V.O. Deposition of titanium silicide on stainless steel AISI 304 surface...................... 127 Pugacheva N.B., NikolinYu.V., BykovaT.M., Goruleva L.S. Chemical composition, structure and microhardness of multilayer high-temperature coatings..................................................................................................................... 138 Saprykina N.А., Chebodaeva V.V., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А., Guseva T.S. Synthesis of a three-component aluminum-based alloy by selective laser melting............................................................... 151 Gabets D.A., MarkovA.M., Guryev M.A., Pismenny E.A., NasyrovaA.K. The effect of complex modifi cation on the structure and properties of gray cast iron for tribotechnical application..................................................... 165 Ivanov I.V., Yurgin A.B., Nasennik I.E. Kuper K.E. Residual stress estimation in crystalline phases of highentropy alloys of the AlxCoCrFeNi system........................................................................................................... 181 Korosteleva E.N., Nikolaev I.O., Korzhova V.V. Features of the structure formation of sintered powder materials using waste metal processing of steel workpieces................................................................................. 192 EroshenkoA.Yu., Legostaeva E.V., Glukhov I.A., Uvarkin P.V., TolmachevA.I., Luginin N.A., Bataev V.A., Ivanov I.V., Sharkeev Yu.P. Effect of deformation processing on microstructure and mechanical properties of Ti-42Nb-7Zr alloy............................................................................................................................................. 206 Kutkin O.M., Bataev I.A., Dovzhenko G.D., Bataeva Z.B. The study of characteristics of the structure of metallic alloys using synchrotron radiation computed laminography (Research Review)................................ 219 EDITORIALMATERIALS 243 FOUNDERS MATERIALS 255 CONTENTS
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 4 4 2 Studies of wear resistance and antifriction properties of metal-polymer pairs operating in a sea water simulator Dena Bataev 1, a, *, Ruslan Goitemirov 1, 2, b, Petimat Bataeva 1, c 1 Kh.I. Ibragimov Complex Institute of the Russian Academy of Sciences, 21a Staropromyslovskoe highway, Grozny, 364051, Chechen Republic, Russian Federation 2 Chechen State Pedagogical University, 33 Subry Kishiyeva St., Grozny, 364037, Chechen Republic, Russian Federation a https://orcid.org/0000-0003-4141-9353, denabataev61@mail.ru, b https://orcid.org/0000-0003-0088-4603, groznymuh@mail.ru, c https://orcid.org/0000-0002-9628-0742, bataeva_ggntu@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2022 vol. 24 no. 4 pp. 84–97 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2022-24.4-84-97 ART I CLE I NFO Article history: Received: 09 September 2022 Revised: 06 October 2022 Accepted: 25 October 2022 Available online: 15 December 2022 Keywords: Polymeric Composite Maslyanit Wear resistant Coefficient of friction Sea water simulator Fatigue wear Acknowledgements Research were partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Sea water is an aggressive environment that causes corrosion, erosion, and cavitation when moving at high speeds of steel, cast iron, bronze, or babbit parts that work satisfactorily only with lubrication. In this case, oil stains are often released into the water, which leads to pollution of the water basin. Materials and methods. To study the wear and friction coefficient, the following materials were chosen: pure polyamide P-610 and antifriction materials based on it Maslyanit D and Maslyanit 12. The following metals were used as the material of the counterbody: stainless steel Cr18Ni9Ti, bronze (9 % Al; 2 % Mn), and titanium alloy VT-3. Results and discussion. It is established that the materials of the “maslyanit” group have significantly better wear resistance and antifriction properties than pure polyamide P-610. It is shown that the reason for such properties of Maslyanit D and Maslyanit 12 is the presence of solid and grease lubricants in its compositions, which simultaneously also play the role of a plasticizer. Finely dispersed metal fillers favorably affect the heat rejection from the friction zone and the growth of the crystalline phase of the polymer. A positive effect of iron minium on the friction of Maslyanit 12, which causes the generation of a protective anti-friction film on the working surfaces of the friction pair, is revealed. A decrease in wear and friction coefficient is found as the purity class of the metal surface increased. The predominantly fatigue mechanism of wear of polymeric materials during friction in a sea water simulator is confirmed. The results of testing Maslyanite 12 in a real marine environment confirmed the positive characteristics of Maslyanit 12. For citation: Bataev D.K-S., Goitemirov R.U., Bataeva P.D. Studies of wear resistance and antifriction properties of metal-polymer pairs operating in a sea water simulator. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 4, pp. 84–97. DOI: 10.17212/1994-6309-2022-24.4-84-97. (In Russian). ______ * Corresponding author Bataev Dena Karim-Sultanovich, D.Sc. (Engineering), Professor, Director Kh.I. Ibragimov Complex Institute of the Russian Academy of Sciences, 21a Staropromyslovskoe highway, 364051, Grozny, Chechen Republic, Russian Federation Tel.: +7 (871) 222-26-28, e-mail: denabataev61@mail.ru Introduction In the products of modern construction, shipbuilding, ship repair and other industries (port and deck mechanisms, technological equipment, watercraft, screw-stern and steering devices, ship centrifugal submersible pumps, equipment for oil production platforms, farms for breeding marine fish, desalination stations), which are in contact with fresh or sea water, are increasingly using polymeric materials. Sea water is a strong electrolyte; it has high electrical conductivity and aeration. The high aggressiveness of this medium, containing in its composition sodium sulfates, sodium chlorides, magnesium, calcium and other salts, cause corrosion, erosion, and cavitation when steel, cast iron, bronze or babbitt parts and assemblies
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 4 No. 4 2022 move at high speeds. These parts and assembles work satisfactorily only in the presence of lubrication. This often results in the re-lease of oil stains into the water, adversely affecting the fauna and flora. Ship shaft bearings (stern tube bearings) operate under extreme conditions. Solving the problem of its reliability and performance in water, especially at high pressures of the deep sea medium, is one of the difficult tasks of materials science [1, 2, 3]. Polyamides and compositions based on it have high wear resistance and a stable coefficient of friction in water and in other media; lubricants can reduce vibration loads and noise and ensure the environmental safety of the water basin. Despite the fact that the presence of a liquid medium, including water, leads to swelling of polymeric materials, it is found that exposure to water stabilizes its dimensions and improves tribological properties [4, 5]. At the same time, in the works by the school of Rehbinder and other researchers [6, 7, 8, 9] the adsorption effect of water and other liquids on the strength of solids due to a decrease in surface energy and its “wedging” effect on walls has become wide-spread. It is assumed that a decrease in the strength of polymers is caused by a change in the surface energy, which leads to a decrease in the critical stress at the crack tip. With this approach, failure is a critical phenomenon that occurs when the stress at the tip of the most dangerous crack reaches the strength of the material. An approach based on the kinetic concept of strength was developed in the works of Bershtein [10, 11, 12], who proceeded from the kinetic concept, according to which destruction occurs as a result of the accumulation of chemical bond breaks under the action of thermal fluctuations, i.e., the destruction in the presence of water molecules is a reaction of mechanically stimulated hydrolysis. In studies on the tribotechnical properties of polymer composite materials, we found [13, 14] that under the dry friction with an oscillating movement of the working surface, with unidirectional linear movement, in the presence of dynamic loading, in abrasive or chemically aggressive media, the leading wear mechanism is fatigue failure of the working layer. The state of the friction surfaces of the pair is characterized by the presence of a certain composition of surface films. In real air conditions, all microasperities and microcracks are almost instantaneously coated with oxide films and layers of adsorbed polymer sample molecules and fillers that are strongly bound to the metal. Typically, oxide layers are located above the juvenile (pure) surface. These films shield the working surfaces of the tribosystem thus contributing to the boundary friction mechanism in the absence of lubrication and “self-organization” of the steady-state friction [15, 16]. The materials used for the manufacture of friction parts should have low friction coefficient and high wear resistance, i.e., optimal basic informative tribotechnical characteristics. Besides, the tribotechnical composite materials require that the materials used as modifiers are able to form friction transfer films (graphite, carbon, polytetrafluorethylene, silicon dioxide, molybdenum disulfide, etc.) during friction and ensure a self-lubricating mode. These requirements can be met by the use of polymer composite materials (PCMs). Most polyamides are characterized by a good combination of these parameters; it retains its properties when exposed to aggressive media [3, 17, 18, 19]. The analysis of various studies shows the need for experimental verification of the behavior of polymer materials in the presence of sea water in the working contact. The purpose of this work is to study the tribotechnical properties of materials based on polyamide in a sea water simulant medium and to compare pure and filled polyamides in terms of its antifriction properties and fatigue wear resistance under various test conditions. This purpose requires the solution of the following tasks: 1) to choose the test materials on the basis of theoretical surveys; 2) to develop a test method and experimental equipment; 3) to perform laboratory tests of chosen materials; 4) to verify laboratory test methods in conditions simulating the actual operation modes of the product. To ensure high reliability of friction units operating in sea water, the correct choice of a friction pair is of great importance. The increased wear observed during the operation of functional units requires new polymer-based anti-friction materials, one of the representatives of which is a group of materials called “Maslyanit.” Due to its unique characteristics in water medium, Maslyanit materials have been widely
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 4 4 2 used in hydraulic structures, port and ship mechanisms instead of rolling bearings, antifriction bronze, babbit, caprolon. Most high-pressure hydropower plants in Russia and the CIS countries use this type of material. Materials and methods The following materials were selected: unfilled pure Polyamide P-610 and antifriction materials on a polymer (Polyamide) basis from the group of “Maslyanit” – Maslyanit D and Maslyanit 12. Metals were used as the material of the counterbody: stainless steel Cr18Ni9Ti, bronze (9 % Al; 2 % Mn), and titanium alloy VT-3. The tests were performed on the end friction machine (Figure 1). The upper head (4) with the test sample (3) is placed into a spindle (8) of the friction machine. The friction unit represents a cup (2) on selfadjustable bearings (11), into which a metal counterbody (9) fixed by a pin against rotation is placed. The friction force was determined using a strain gauge (1). Loading was ensured by a lever system (5, 6, 7) and a load (10). A sea water simulator is poured into the cup 25–30 mm above the friction plane, prepared in the following percentage ratio (to the working medium) of the main components: (NaCl – 2,42 %; СаCl2 – 0,12 %; NaSO4 – 0,4 %; Мg Cl2 – 1,1%)·6Н2О. The unit was cooled from overheating with an air stream using a fan. The test material samples represent annulus cross section plugs with slots in the form of sectors to ensure continuous access of the working medium (sea water simulator) to the friction zone. The contact ratio K = 1/3 (ratio of contact area to the full surface of the ring section). The shape and dimensions of Fig. 1. End friction machine
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 4 No. 4 2022 Fig. 2. Sample shape and dimensions the sample are shown in Figure 2. The samples were manufactured by injection molding, followed by thermal and mechanical processing. The roughness of the friction surfaces of all test samples and counterbodies corresponded to class 7 (Ra = 0.8 μm). Test method. Before the start of the experiment, the sample and the counterbody were kept for 24 hours in a sea water simulator, then degreased with gasoline and acetone. For all variants of friction pairs, comparative tests were carried out at the following modes: - specific load Psp = 4.5 MPa; - linear speed along the average radius of the sample V = 0.14 m/s. The experiment lasted 11 hours. Current measurements were made every 1 hour during the running-in of the samples in order to determine the point of transition of the running-in mode to the stationary (steady-state) wear mode and after 6 hours – after the stabilization of the process. The linear wear of the material was measured on a vertical optimeter with an accuracy of 0.001 mm on three friction areas (A, B, C) separately and averaged. Results and Discussion The results of wear over time are shown in Table 1; according to the averaged values of three tests (Experiments), its graphical representation is presented in the form of histograms (Figure 3). Table 1 and Figure 3 show that the materials of the Maslyanit group have better wear resistance than pure Polyamide P-610. It should be assumed that the reason for the high wear resistance of Maslyanit D and Maslyanit 12 having the same polyamide base (matrix) is the presence of both solid and grease oil in its compositions, which simultaneously act as a plasticizer. The fillers of these compositions are fine metal powders, which increase the thermal conductivity of the material and reduce local temperatures in the friction zone [18]. In addition, the particles of these powders, being the centers of crystal formation, increase the crystalline phase of the material, which has a positive effect on its wear resistance [18, 19]. Comparing Maslyanites with each other, it should be noted that for Maslyanit D, the wear rate stabilizes after surface running-in, while for Maslyanit 12, even after the experimental time (11 hours), there is a large scatter of this evaluation parameter: zero wear when working with steel in one of the experiments Fig. 3. Wear rates of metal-polymer friction pairs in a sea water simulator
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 4 4 2 Ta b l e 1 The results of wear resistance of metal-polymer friction pair in the sea water simulator (wear rate, µm/h) Sample material Steel Bronze Titanium alloy Polyamide P-610 Experiment 1 25.0 11.6 90.3 Experiment 2 69.0 35.6 210.0 Experiment 3 21.4 5.9 223.0 Maslyanit D Experiment 1 5.2 9.6 26.5 Experiment 2 5.2 1.5 10.2 Experiment 3 0.5 3.1 8.8 Maslyanit 12 Experiment 1 0.0 0.72 8.0 Experiment 2 3.3 17.2 42.4 Experiment 3 174.0 0.055 3.7 and high (174 µm/h) in the other (Table 1). Obviously, this “false wearless” can be explained by the presence of iron minium, which generates a thin film on the friction surface. As is known, iron minium – iron oxide Fe2O3 – is used to create the corrosion-resistant and moisture-proof coating of structures. In case of friction in salt water, a thin tear-resistant film is most likely generated on the friction surface. It should be noted that complex physicochemical changes associated with the development of competing processes of destruction and structuring occur during the formation of the friction transfer film in the surface layer of the polymer body. From the point of view of thermodynamics and structural and energy self-organization, the initial stage of friction (running-in) is characterized by the intensive destruction of the initial structures and formation of new, so-called tribostructures with higher antifriction properties. At the same time, some kind of the self-organization of the tribosystem takes place [18–21, 22]. All three tested materials (Figure 3) have significantly worse results in friction with titanium than in friction with steel and bronze; this is typical for titanium alloys [21, 23]. The antifriction properties of Maslyanites during friction with all metal counterbodies are better than that of Polyamide P-610 (Figures 4–6). In addition, Polyamide P-610, within the entire resource of the experimental time (11 hours), when tested in tandemwith steel and bronze, is characterized by a constant increase in the friction coefficient instead of its stabilization. The friction coefficient peak for Polyamide P-610 (Figure 6) in tandem with a titanium counterbody (increasing to 0.7) is correlated with the wear test results (Figure 3), showing the limit value of the wear rate (178 µm/h) for all ex-applications. Destructive processes in the friction zone can explain a sharp decrease in the friction coefficient during its catastrophic wear. Fig. 4. Dynamics of friction coefficients values of a pair: stainless steel 12Cr18Ni9Ti and polymeric material during the completion of the running-in process
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 4 No. 4 2022 Fig. 5. Dynamics of friction coefficients values of a pair: bronze (9 % Al; 2 % Mn) and polymeric material during the completion of the running-in process Fig. 6. Dynamics of friction coefficients values of a pair: titanium alloy VT-3 and polymeric material during the completion of the running-in process In turn, the nature of the running-in process of the metal-polymer friction pair, which largely determines the further life of the working unit of the mechanism, depends on the hardest surface grade of finish [24, 25]. To study the influence of this factor (roughness) on the tribotechnical properties of the metal-polymer pair, bronze (9 % Al; 2 % Mn) and Maslyanit 12, the wearless properties of which were of particular interest for further studies, were selected. Bronze counterbodies were made with five different grades of surface finish. Each test was performed according to the above procedure for one hour. The test results are presented in Table 2 and shown graphically (Figure 7–9). Water, including sea one, which negatively affects the friction of metal pairs, favorably affects the friction process of Maslyanites. This is explained by the hydrodynamic effect that occurs in the contact zone in addition to separation oxide film mentioned above. It should be noted that in units with frequent stops or with the possibility of abrasive getting into it, friction occurs with permanent running-in. This is due to the transition of hydrodynamic friction to boundary friction, which wear is 3–4 times higher than in liquid friction [23]. The graphs of the effect of counterbody surface roughness on hourly mean wear and wear per kilometer of slip path traveled (Figure 7 and 8) are identical and tend to reduce wear as the roughness of the metal surface decreases.
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 4 4 2 Ta b l e 2 Results of the effect of metal surface roughness on a metal-polymer friction pair operation in a sea water simulator Sequence number Counterbody roughness parameter – Ra, μm Mean hourly wear of Maslyanit 12, μm/h Mean wear of Maslyanit 12 per 1 km of track, µm/km Friction coefficient 1 3.2 30.6 9.05 0.0450 2 1.6 22.0 6.5 0.0391 3 0.8 20.3 6.0 0.0309 4 0.4 10.0 2.96 0.0236 5 0.2 8.6 2.62 0.0200 Fig. 7. Influence of the counterbody roughness on the average hourly wear of Maslyanite 12 Fig. 8. Influence of the counterbody roughness on the wear of Maslyanite 12 per 1 km of the friction path It should be expected that since a surface with a greater roughness, like blades, better captures and tightens the lubricating medium (in our case, the seawater simulator) into the contact gap, it should favor the creation of increased pressure and hydraulic wedge in contact, which ensures the “flotation” of the shaft.
OBRABOTKAMETALLOV MATERIAL SCIENCE Том 23 № 3 2021 EQUIPMEN . INSTRUM TS Vol. 4 No. 4 2022 Fig. 9. Influence of the counterbody roughness on the coefficient of friction of Maslyanyt 12 However, many factors influence the hydrodynamic friction effect: specific pressure, sliding speed, medium viscosity, etc., the optimum of which is difficult to ensure not only in real practice, but also at the research stage, which is confirmed by these studies. As a result, increased wear of the polymer composition prevails during the running-in and micro running-in period due to the cutting action of the bronze surface microasperities. A film of macromolecules of polyamide, bronze decomposition and iron minium formed in the initial period of friction because of tribodestruction are preserved in the surface deformable layers of the composite and on the working surface of the counterbody. The positive tendency to reduce wear and friction with an increase in the grade of surface finish can be explained by a softer smoothing of the small microasperities of the counterbody, faster running-in, lapping of working surfaces and, therefore, the early steady-state wear process and the “self-organization” of the tribosystem. Bench tests in seawater The tests were performed near Sochi (Lazarevskoye). Since significant heating of the material may occur during friction due to the low thermal conductivity of plastics and heat removal from the friction zone, mainly only through a metal counterbody, and also considering that in addition to the load from the transmitted working force the units of real sea vessels and deep-sea equipment also experience water pressure, it was necessary to conduct tests as close as possible to real operational conditions. A bench of deep-sea field tests was created to conduct these studies. This test bench represented a chamber into which sea water was supplied using a high-pressure pump (up to 200 atm.). Bronze (9 % Al; 2 % Mn) and Maslyanit 12 were chosen as friction pair materials for comparison of laboratory and bench results. The test samples were in the form of ø 80×50×26 half-liners (Figure 10) and internal grooves to provide continuous access of the lubricant – sea water – to the friction zone. To relieve internal stresses, samples made by injection molding were heat treated in Vapor oil. Prior to testing, the samples were kept in sea water for 24 hours. The tests were performed at a specific load of 2.5 MPa and a sliding speed of 0.3 m/s. The measurements were taken every 3 hours during running-in and 50 hours after the steady-state wear. The total duration of the test was 670 hours. Measurement points were marked according to the template. The period of friction running-in lasted 72 hours, after which the wear rate was set at 0.5–0.8 μm/h. As a result of visual inspection and measurements of samples performed at the end of the tests (average wear
OBRABOTKAMETALLOV Vol. 23 No. 3 2021 MATERIAL SCIENCE EQUIPMENT. INSTRUMENTS 4 4 2 Fig. 10. Samples of Maslyanit 12 after bench tests in sea water less than 0.5 mm), it was found that there are no traces of tearing, catastrophic wear, melting and other abnormal processes on the friction surfaces. At the same time, wear and tear of the bronze shaft, which was paired with Maslyanit 12, was not detected. Conclusion The study of the tribotechnical properties of materials based on polyamide in the medium of a sea water simulator made it possible: – to choose the test materials on the basis of theoretical surveys; – to develop a test method and experimental equipment; – to perform laboratory tests of chosen materials. It was revealed that the friction pair bronze (9 % Al; 2 % Mn) and Maslyanit 12 has high antifriction properties and wear resistance when operating in a sea water simulator; the wear and friction coefficient of the studied friction pair is less than the metal surface grade of finish; – to verify laboratory test methods in conditions simulating the actual operation modes of the product. It was established that the results of laboratory and bench tests are correlated with each other and allow for the further use of the laboratory test method for the preliminary selection of optimal friction pairs operating in sea water; – to confirm that wear of filled polyamide composite materials of the Maslyanit group in the considered media after the completion of the running-in process occurs mainly by the fatigue mechanism, which is facilitated by the protective film adsorbed on the working surfaces. – to recommend the selected and studied friction pair for use in various options (shaft-plug, sliding guides, etc.) for bearings, thrust bearings, movable supports and guides of construction, shipbuilding, ship repair industries (port and deck mechanisms, process equipment, floating rigs, high-speed hydrofoil passenger ships, propeller and steering devices, ship centrifugal submersible pumps, equipment for oil production platforms, marine fish farms, desalination and power plants, etc.), which are in contact with fresh or sea water.
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