Issue |
Wuhan Univ. J. Nat. Sci.
Volume 29, Number 5, October 2024
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Page(s) | 484 - 494 | |
DOI | https://doi.org/10.1051/wujns/2024295484 | |
Published online | 20 November 2024 |
Materials Science
CLC number: TH117
Wear Properties of Ni3Al-Ni3V-Zr-Ni5Zr Alloys under Different Atmospheres
不同气氛下Ni3Al-Ni3V-Zr-Ni5Zr合金的磨损特性
Hunan Provincial Key Laboratory of Mechanical Equipment Health Maintenance, Hunan University of Science and Technology, Xiangtan 411201, Hunan, China
† Corresponding author. E-mail: zhsh_w@sina.com
Received:
3
November
2023
The study examines the friction and wear properties of Ni3Al-Ni3V-Zr-Ni5Zr alloys under varying gas conditions. The alloy was tested in the presence of oxygen and carbon dioxide using a controlled atmosphere wear tester. The study revealed that the wear environmental embrittlement resulted from the diffusion of reactive atomic hydrogen into the interior of the Ni3Al-Ni3V alloy. The addition of Zr elements decreased the proportion of Al elements on the surface of the Ni3Al-Ni3V-Zr-Ni5Zr alloy and reduced the proportion of H atoms produced by the chemical reaction between atmospheric water vapour and Al elements. This inhibited the environmental embrittlement and improved the performance of the Ni3Al-Ni3V-Zr-Ni5Zr alloy. The wear performance of Ni5Zr alloy is superior to that of Ni3Al-Ni3V. When exposed to air in an air environment, the surface of Ni3Al-Ni3V-Zr-Ni5Zr alloy forms a protective Al2O3 oxide film on the workpiece, resulting in a reduction of the friction coefficient and wear rate of the alloy. The wear mechanism of the alloy is mainly oxidation wear and abrasive wear. In an oxygen environment, the surface of the alloy generates a significant amount of Al2O3 oxide film. The flaking of the oxide film leads to an increase in the friction coefficient and wear rate of the alloy. In a carbon dioxide environment, the surface of the alloy undergoes severe deformation, and plough lines become apparent. This is accompanied by flaking Si3N4 abrasive chips adhering to the surface of the alloy, which intensifies the wear of the alloy. The primary wear mechanism is abrasive wear. Therefore, the friction coefficient and wear rate of the Ni3Al-Ni3V-Zr-Ni5Zr alloy in the atmosphere are optimal.
摘要
本研究探讨了Ni3Al-Ni3V-Zr-Ni5Zr合金在不同气体条件下的摩擦和磨损特性。使用可控气氛磨损测试仪在氧气和二氧化碳存在的条件下对合金进行了测试。结果表明: 磨损环境致脆是由活性原子氢扩散进入Ni3Al-Ni3V合金内部引起的; Zr元素的加入贫化了Ni3Al-Ni3V合金表面的Al元素, 降低了大气中的水汽与Al元素结合产生H原子的比例, 抑制了环境致脆。大气中Ni3Al-Ni3V-Zr-Ni5Zr合金表面暴露在空气中生成Al2O3氧化膜保护了工件, 使得合金摩擦系数和磨损率降低, 磨损机制主要为氧化磨损与磨粒磨损; 氧气气氛下, 合金表面生成大量Al2O3氧化物膜, 氧化物膜的剥落导致合金的摩擦系数和磨损率增加, 合金主要磨损机制为氧化磨损、粘着磨损与磨粒磨损; 二氧化碳环境下, 合金表面塑性变形严重, 犁沟明显, 伴随着剥落的Si3N4磨屑粘附在合金表面, 加剧了合金的磨损, 主要磨损机制为磨粒磨损; 因此, Ni3Al-Ni3V-Zr-Ni5Zr合金在大气下的摩擦系数和磨损率最优。
Key words: metallic materials / Ni3Al-Ni3V-Zr-Ni5Zr alloys / environmental embrittlement / nickel-based alloys / frictional wear
关键字 : 金属材料 / Ni3Al-Ni3V-Zr-Ni5Zr合金 / 环境致脆 / 镍基合金 / 摩擦磨损
Cite this article: WU Shang-a-meng, WANG Zhensheng. Wear Properties of Ni3Al-Ni3V-Zr-Ni5Zr Alloys under Different Atmospheres[J]. Wuhan Univ J of Nat Sci, 2024, 29(5): 484-494.
Biography: WU Shang-a-meng, male, Master candidate, research direction: friction and wear of materials. E-mail: 21020301050@mail.hnust.edu.cn
Fundation item: Supported by the Natural Science Foundation of Hunan Province of China (2020JJ4312)
© Wuhan University 2024
This is an Open Access article distributed under the terms of the Creative Commons Attribution License (https://creativecommons.org/licenses/by/4.0), which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
0 Introduction
As space exploration advances, the environmental conditions in space are becoming harsher. The demands placed on exploration machines and their components are increasing. Aerospace materials have become critical to the success of space exploration. Bearings are the heart of space machines. Bearings are a crucial component of machines due to their excellent resistance to pressure, corrosion, wear, and self-lubrication. The materials used to make bearings are of utmost importance. Ni3X intermetallic compounds with geometrically close packed (GCP) structures exhibit high stability and strength, as well as excellent oxidation and corrosion resistance at high temperatures. However, it has been observed that these compounds have poor ductility at room temperature and low creep strength at high temperatures. To address these issues, microstructures based on Ni3X (where X is Al, Ti, and Nb, or Si, Ti, and Nb, or Al, Ti, and V, or Al, Nb, and V) have been extensively studied. Among these alloy systems, the dual-phase, two-phase intermetallic alloy Ni3Al-Ni3V is particularly well-suited for high-temperature mechanical components. This two-phase metal alloy exhibits a unique microstructure, with high interconnectivity, and is significantly more highly alloyed than many conventional metal alloys[1].
Ni3Al-Ni3V two-phase metal compounds are considered to be some of the best candidates for bearings in important machines in the land, marine, and aerospace gas turbine industries[2]. To enhance the mechanical properties of bearings, scholars have incorporated solid solution strengtheners into two-phase alloy materials. For instance, Ta with Re[3], Nb with Ti[4], NbC[5], Fe[6], and C[7] have been used. Research has shown that the inclusion of Zr elements has a plasticizing effect on Ni3Al-rich alloys[8]. Additionally, the addition of Zr improves the ductility and oxidation resistance of Ni3V alloys[8-11]. Furthermore, Zr in the Ni phase region is beneficial for enhancing the stability of O within the Ni-Ni3Al system[12]. Intermetallic compounds that contain aluminium are highly susceptible to hydrogen embrittlement, which occurs when atmospheric water vapour reacts with the aluminium element in the alloy to form hydrogen, leading to embrittlement of the material. However, the addition of zirconium elements to nickel-based alloys suppresses environmental embrittlement of the alloy and provides better wear properties than Ni3Al-Ni3V alloys[13]. However, research on the friction and wear characteristics of nickel-based alloys that contain zirconium elements is limited. There are few studies on complex gaseous environments similar to those in outer space. Therefore, this paper focuses on studying the friction and wear properties of Ni3Al-Ni3V-Zr-Ni5Zr alloys in different atmospheres, such as air, oxygen (O2), and carbon dioxide(CO2). It compares these properties with those of Ni3Al-Ni3V alloys. The study aims to provide a better understanding of the friction and wear properties of these alloys in different environments.
1 Experimental Materials and Methods
1.1 Alloy Preparation
High purity Ni, Al, V and Zr were selected and melted into ϕ100 mm×15 mm ingots using a DHL-1250 high vacuum induction furnace. The actual chemical composition (mole fraction) of the melted alloys was 76.18Ni-8.75Al-14.92V-0.15Zr (referred to as Ni3Al-Ni3V-Zr-Ni5Zr alloy) and 76.21Ni-8.92Al-14.87V (referred to as the Ni3Al-Ni3V alloy).
1.2 Alloy Heat Treatment Processes
The alloy underwent heat treatment using a ZM-45-15 vacuum molybdenum wire furnace. The heat treatment process for this alloy is shown in Table 1. A wear specimen measuring 35 mm×35 mm×7 mm was wire cut and its surface was ground using 800 grit sandpaper.
Heat treatment processes for alloys
1.3 Experimental Methods
The friction and wear test is conducted using the WTM-2E controlled atmosphere miniature friction and wear tester. A vacuum hood is used to seal the specimen and the friction and wear apparatus. The chamber is evacuated before the test to remove the air from it. Then, the chamber is cleaned by passing in the gas required for the test. This process is repeated four times while the chamber continues to be evacuated. Friction and wear tests were conducted in three different atmospheres: air, O2, and CO2. A controlled flow of 0.05 MPa of O2 and CO2 was maintained, along with an ambient humidity of 10%-14% (measured by an Anymetre JR900 electronic hygrometer). The sample is to be rubbed with a 5 mm Si3N4 ball. The wear test involved applying pressure loads of 3, 10, and 20 N to the alloy wear specimen using a rotating ceramic ball. The sliding speed was set at 0.1 m/s, and the test lasted for 30 min. The friction coefficient was automatically recorded by the instrument. The wear depth and width of the specimens were measured using a NanoMap-500LS 3D contact surface profiler. The calculation of the wear rate is determined by the formula W=V /(F·L). Here, W represents the wear rate, V represents the wear volume, F represents the load, and L represents the wear distance. The FM-700e Vickers hardness tester was used to test the material hardness. The wear surface morphology and alloy microstructure were observed using a QUANTA 250 scanning electron microscope. The composition was analyzed with an energy spectrometer, and the volume fraction of the Ni3Al phase was analyzed using Image J software.
2 Results and Analysis
2.1 Microstructure and Hardness Analysis of the Alloys
Figure 1 displays the histomorphology and X-Ray diffraction (XRD) patterns of the Ni3Al-Ni3V and Ni3Al-Ni3V-Zr-Ni5Zr alloys. The black phase of the alloys is the Ni3V (L12) precipitated phase, while the grey phase is the two-phase composite microstructure of Ni3Al and Ni3V[13]. These findings are supported by the energy dispersive spectrometer (EDS) analysis results presented in Table 2.
Fig. 1 Microstructure and XRD patterns of Ni3Al-Ni3V and Ni3Al-Ni3V-Zr-Ni5Zr alloys (a) Ni3Al-Ni3V; (b) Ni3Al-Ni3V-Zr-Ni5Zr-Sample 1; (c) Ni3Al-Ni3V-Zr-Ni5Zr-Sample 2; (d) Ni3Al-Ni3V-Zr-Ni5Zr-Sample 3; (e) Ni5Zr-phase; (f) XRD of alloys |
The high structural stability of the two-phase structure[14,15] results in superior high-temperature mechanical properties, such as tensile and creep strength, compared with many conventional high-temperature alloys. The Ni3Al-Ni3V-Zr-Ni5Zr alloy contains a high Zr content in the white phase. The transmission electron microscope (TEM) analysis reveals the presence of the brittle Ni5Zr phase in this region, which results in poor plasticity throughout the workpiece[16]. Sample 1 has a Ni3Al phase size of approximately 250 nm, sample 3 has a Ni3Al phase size of approximately 500 nm, and sample 2 has a Ni3Al phase size of approximately 1-4 μm. The nanoscale structure is the primary cause of the "bun peaks" in samples 1 and 3 XRD patterns.
Table 3 presents the hardness data for various materials relative to the hardness of Ni3Al-Ni3V, which ranges from 498.3 to 521.4 HV. Additionally, the volume fractions of Ni3Al in samples 1, 2, and 3 were 41.601%, 62.179%, and 55.216%, respectively. The Ni3Al+Ni3V phase is the hard phase, while the Ni3Al phase is the soft phase. Therefore, as the volume fraction of Ni3V increases, the alloy's hardness decreases.
Chemical composition of each marked area in Fig. 1(c) %
Vickers hardness of different materials (unit:HV)
2.2 Frictional Wear Properties of the Alloy
Figure 2(a) displays the friction coefficients for the Ni3Al-Ni3V and Ni3Al-Ni3V-Zr-Ni5Zr alloys. The coefficient of friction for all alloys decreases with increasing load. In an air environment, the coefficient of friction of the Ni3Al-Ni3V alloy is significantly larger than that of the Ni3Al-Ni3V-Zr-Ni5Zr alloy. The coefficient of friction of the Ni3Al-Ni3V-Zr-Ni5Zr alloy is highest in an O2 environment, followed by CO2 and air environments. Figure 2(b) displays the wear rates of the Ni3Al-Ni3V and Ni3Al-Ni3V-Zr-Ni5Zr alloys. It is evident that the wear rate of the Ni3Al-Ni3V alloy is significantly higher in the air environment compared to that of the Ni3Al-Ni3V-Zr-Ni5Zr alloy. Additionally, the wear rate of the Ni3Al-Ni3V-Zr-Ni5Zr alloy is higher in the CO2 environment than in the O2 environment and air environment. At low load, the wear rate of the Ni3Al-Ni3V-Zr-Ni5Zr alloy is the same in both air and O2 environments. As the load increases, the wear rate in the air environment remains relatively stable, while in the O2 environment it increases rapidly.
Fig. 2 Comparison of alloy friction coefficients (a) and wear rates (b) |
2.3 Wear Surface Morphology
Figure 3 displays the wear surface morphology of the Ni3Al-Ni3V alloy under air conditions. At a load of 3 N, the surface of the alloy exhibits significant cracks, characterized by ploughing, spalling, and slight adhesion, with blocky spalling around the cracks. This is where the friction coefficient and wear rate of the alloy reach their maximum. As the load increases to 10 N, ploughing and adhesion become more pronounced, while cracking weakens and the alloy's coefficient of friction and wear rate decrease significantly. When the load increases to 20 N, adhesion increases, cracking weakens further, and the alloy's wear rate and coefficient of friction decrease even more. Furthermore, observations of the parallel wear surface indicate the presence of a distinct sharp angle feature and cracking characteristics. Cracks were observed sprouting on the wear surface and expanding in a direction approximately 18 degrees from the wear surface (Fig. 3(d)), indicating hydrogen embrittlement cracking characteristics. Therefore, both load and hydrogen embrittlement significantly influence the frictional wear properties of the Ni3Al-Ni3V alloy.
Fig. 3 Surface abrasion profile of Ni3Al-Ni3V alloy (a) 3 N; (b) 10 N; (c) 20 N; (d) Crackle |
The EDS analysis and the wear surface morphology of the three Ni3Al-Ni3V-Zr-Ni5Zr alloys are displayed in Table 4 and Figs 4 to 6, respectively. The wear surfaces of the alloys under air conditions (Figs. 4(a)-(c), 5(a)-(c) and 6(a)-(c)) exhibit mainly ploughing and adhesion (Fig. 4(b)-I). The EDS analysis (Table 4) shows a high content of Ni and O elements in this adhesion, along with a small amount of cracking and spalling features on the alloy surfaces. As the load increases, the adhesion features weaken, and the grooved features slightly increase. The weakened adhesion features reduce the friction coefficient of the alloy.
Fig. 4 Surface wear of alloys of Sample 1 (a)-(c): Air of 3, 10 and 20 N; (d)-(f): O2 of 3, 10 and 20 N; (g)-(i): CO2 of 3, 10 and 20 N |
The wear surfaces of the alloy in O2 (Figs. 4(d)-(f), 5(d)-(f), and 6(d)-(f)) exhibit more pronounced grooving, adhesion, and spalling features than in the air. There is also a small amount of surface cracking (Fig. 4(e)-II) and an increased loading of black material (Fig. 4(f)-III). The oxygen content (Table 4) and surface black material are also increased. According to EDS analysis, the black material found at the wear site is Si compounds that were transferred from Si3N4. The high O content observed at the cracked features of the alloy wear surface indicates that an oxide film covered the wear surface. Energy spectral analysis revealed a large number of spalling bands on the wear surface (Fig. 5(d)-IV), which were identified as the alloy matrix. It can be inferred that these bands were caused by Si3N4 cutting the alloy matrix. The wear surface of the alloy in the CO2 environment exhibited slight ploughing, adhesion, and spalling features at 3 N load, with a small amount of flake spalling also observed. The adhesion features appeared powder-like. At 10 N load, the ploughing on the wear surface increased, and slight plastic deformation occurred, along with cracks perpendicular to the direction of wear.
Fig. 5 Surface wear of alloys of Sample 2 in different atmospheres (a)-(c): Air of 3, 10 and 20 N; (d)-(f): O2 of 3, 10 and 20 N; (g)-(i): CO2 of 3, 10 and 20 N |
Chemical composition (mole fraction) at each wear surface mark in Figs. 4 to 6 (unit:%)
3 Discussion
3.1 Analysis of the Frictional Properties
In Fig. 2(a), it can be observed that Sample 2 has a slightly larger coefficient of friction compared to Samples 1 and 3. This is due to the fact that the hardness of the material has a significant impact on the coefficient of friction. As the hardness increases, the contact area between the workpiece and the two objects that rub against each other decreases[17], and the frictional wearability of the material is directly proportional to the hardness[18]. Thus, the coefficient of friction of sample 2 is higher than that of samples 1 and 3.
The coefficient of friction of the Ni3Al-Ni3V and Ni3Al-Ni3V-Zr-Ni5Zr alloys tends to decrease with increasing load (Fig. 2(a)) due to the fact that the coefficient of friction is determined by the ratio of the shear strength to the yield strength of the softer of the two metals that rub against each other. The ratio of shear strength to yield strength of the same metal is determined by the fact that the shear strength and yield strength of the same metal are certain and that they vary simultaneously. During frictional wear, the heat generated by friction is confined to the surface layer. At higher loads, the change in shear strength is more pronounced for softer metals compared to yield strength, leading to a decrease in the coefficient of friction, i.e. the decrease in shear strength is confined to the surface layer of the metal and the metal matrix remains very large The change in yield strength follows the trend of Ref. [17].
3.2 Cracking and Environmental Embrittlement Mechanisms on Wear Surfaces
According to Hertz's classical equation (1)[17], the Ni3Al-Ni3V alloy produced significant cracking features on the wear surface (Fig. 3), while the Ni3Al-Ni3V-Zr-Ni5Zr alloy had no significant cracking features on the wear surface (Figs. 4 to 6). An analysis was carried out.
where a (mm) is the radius of the contact zone, r (mm) represents the radius of the collimated sphere Si3N4, F(N) represents the load, and E1 (GPa) and E2 (GPa) represent the modulus of elasticity of Si3N4 and the sample alloy, respectively (refer to Tables 5 and 6). A= πa2 will be proportional to W2/3 and the average pressure in the contact zone, Pm=W/πa2 will be proportional to W1/3[17]. Equation (1) calculates A for the Ni3Al-Ni3V alloy and the Ni3Al-Ni3V-Zr-Ni5Zr alloy at different loads (Tables 5 and 6). The results show that the true contact surface is in plastic contact, and this is deduced from the value of E1, which is approximately 310 GPa.
In terms of strength factor, Gerberich et al[19] concluded that the effective stress field strength factor at the crack tip is KI, which increases with the number of dislocations emanating from the crack tip, and when it is greater than or equal to KIC, the material should fracture, which is referred to as "plasticity-induced disintegration".
In Eq. (2), KI is the crack tip stress intensity factor. According to the calculation, it can be seen that KI of Ni3Al-Ni3V (1.63 (MPa·m)1/2) is much smaller than KIC of Ni3Al-Ni3V (>20 (MPa·m)1/2), so the Ni3Al-Ni3V alloy wear surface cracking is not caused by contact stress.
The environmental sensitivity of nickel aluminium alloys increases with increasing aluminium content due to the higher activity of aluminium compared to nickel. This is reflected in the decreasing free enthalpy change of reaction with water vapour, with the order of Ni < Ni94Al6 < Ni3V < NiAl < NiAl3[20]. Table 6 displays the Gibbs free energy for the reaction of each element with water vapour in the Ni3Al-Ni3V alloy. When the Gibbs free energy of each element in the alloy is less than -120 kJ/mol, the alloy becomes highly sensitive to the environment[20]. The main cause of environmental hydrogen embrittlement in the alloy is the reaction of Al and V elements with water vapour, which produces H atoms.
In comparison to the air wear surface of the Ni3Al-Ni3V alloy shown in Figs. 3(a)-(c), the air wear surfaces of the Ni3Al-Ni3V-Zr-Ni5Zr alloys in Fig. 4 (a)-(c), Fig. 5(a)-(c) and Fig. 6 (a)-(c) exhibit minimal crack generation. This is attributed to the presence of Zr, an oxygen-loving element that is distributed within the grain as an oxygen trap, thereby preventing oxygen from entering the grain boundaries and reducing oxygen levels. The diffusion of oxygen along the grain boundaries is reduced, which in turn reduces the generation of grain boundary cracks. The plasticity of the alloy is improved by the bias and diffusion of Zr elements to the grain boundaries[22]. Additionally, the element Zr readily forms an oxide film of Zr with oxygen that covers the surface of the workpiece. Pre-oxidation of the sample produces a protective oxide film that reduces the material's susceptibility to hydrogen embrittlement[23]. The presence of Zr results in the consumption of surface Al in the alloy. This reduces the proportion of H atoms produced by the combination of Al and atmospheric moisture, leading to an improvement in environmental embrittlement[13].
Fig. 6 Surface wear of the alloy of Sample 3 in different atmospheres (a)-(c): Air of 3, 10 and 20 N; (d)-(f): O2 of 3, 10 and 20 N; (g)-(i): CO2 of 3, 10 and 20 N |
Contact area, mean stress and mechanical properties of alloys
Gibbs free energy of the reaction of the main elements of the alloy with water vapour
3.3 Mechanisms for the Influence of Oxide Films on the Frictional Wear Properties of Alloy Surfaces
When elements such as Al in the Ni3Al-Ni3V-Zr-Ni5Zr alloy are exposed to air, oxides such as aluminium oxide are formed with water vapour and O2 in the air, and the friction surfaces are rapidly oxidized as soon as they come into contact with air. The oxidation does not take long, and an oxide film 10 to 100 angstroms thick can be obtained in a short time[17], and this oxide provides good protection for the alloy substrate. Therefore, the main wear mechanisms of the Ni3Al-Ni3V-Zr-Ni5Zr alloy in the air environment are oxidative and abrasive wear, with low friction coefficients (Fig. 2(a)) and wear rates (Fig. 2(b)).
In an O2 environment, the oxygen concentration is approximately 2.5 times that in air due to the O2 pressure of 0.5 MPa. According to Table 7, Zr and Al will preferentially react with O2 to form ZrO2 and Al2O3 (Zr+O2 = ZrO2 with 4/3Al+O2 = 2/3Al2O3 ), V will react with O2 to form V2O5 (4/5V+O2 = 2/5V2O5 ), V2O5 and Al to form Al2O3, and in the chemical formula 4/3Al+O2= 2/3Al2O3 with low Gibbs free energy synergy, the alloy surface will continue to produce Al2O3 oxide film; accompanied by friction-induced surface temperature increase, the wear surface rapidly reacts to generate oxide film, which on the one hand protects the workpiece surface, but when the oxide film superimposed reaches a thickness of 200 Å, the oxide film may break, increasing the friction coefficient of the alloy[17]. When the load is 3 N, the temperature rise of the wear surface and the ploughing of the micro convex body on the Si3N4 surface of the wear part are weak, and the oxide film is generated and peeled off at a slower rate, resulting in a lower wear rate of the alloy. When the load is 10 N (Fig. 4(e), Fig. 5(e), Fig. 6(e)), the temperature of the alloy surface rises rapidly in frictional wear, the oxygen atoms become more active, accelerating the formation of oxides, and when the oxide film reaches a certain thickness, it becomes fragile and easily cracks or flakes off. The wear rate of the alloy then increases. At a load of 20 N (Fig. 4(f), Fig. 5(f) and Fig. 6(f)), the oxide film on the wear surface rubs violently against its Si3N4 counterpart, resulting in violent flaking of the oxide film against the Si3N4, and the flaked Si3N4 fragments are transferred to the wear surface of the alloy. These hard Si3N4 shear forces combine with the high load to increase the alloy's wear, and the alloy's wear rate (Fig. 2(b)) continues to increase. In the O2 environment, the main wear mechanisms are oxidative and adhesive wear at low loads and abrasive and oxidative wear at high loads.
Gibbs free energy of the reaction of the main elements of the alloy with O2
3.4 Mechanisms for the Formation of Oxide Films on Alloy Wear Surfaces
A simplified model is proposed based on the analysis of the frictional wear process of the Ni3Al-Ni3V-Zr-Ni5Zr alloy, as shown in Fig. 7. In the early stages of wear, friction tends to be unstable due to insufficient frictional heat and the presence of elements such as Zr, Al, and Ni distributed in the alloy (Fig. 7(a)). As wear progresses, the material surface undergoes plastic deformation accompanied by extrusion deformation, generating a large amount of frictional heat. During extrusion and deformation (as shown in Fig. 7(b)), elements like Zr, Al, and Ni tend to accumulate towards the surface. These elements then react with oxygen to form their respective oxides (such as ZrO2, Al2O3, and NiO) which are compressed to create oxide films that adhere to the surface (as seen in Fig. 7(c)). As wear continues, cyclic loading leads to a gradual reduction in wear flakes, a gradual build-up of frictional heat, an increase in the adhesive properties of the oxide film, and gradual compaction of the oxide film (see Fig. 7(d)). The thickness of the oxide film increases gradually under the load compaction. However, when the oxide film reaches a thickness of 200 Å, it becomes brittle and tends to crack or flake off (see 1 in Fig. 4(e)). Continued friction results in the production of a new oxide film, leading to flaking and an increase in wear rate. This cycle repeats, further increasing the wear rate. Localized oxide films can break down under excessive contact stress, causing surface oxide particles to enter the coating and slightly increasing the coefficient of friction and wear rate.
Fig. 7 Mechanisms for the formation of alloy oxide films |
4 Conclusion
1) The addition of Zr elements to the Ni3Al-Ni3V alloy resulted in a significant decrease in its hardness. Furthermore, an increase in the volume fraction of Ni3V in the alloy led to a decreasing trend in its hardness.
2) The magnitude of the friction coefficient of Ni3Al-Ni3V-Zr-Ni5Zr alloy follows the order of O2 environment > CO2 environment > air environment, while the magnitude of the wear rate follows the order of CO2 environment > O2 environment > air environment. The addition of Zr is important to the frictional wear performance of Ni3Al-Ni3V-Zr-Ni5Zr alloy, which exhibits better friction coefficient and wear rate than Ni3Al-Ni3V alloy.
3) The wear surface cracks on Ni3Al-Ni3V alloys are not caused by contact stress, but rather by H atoms generated through the reaction of Al elements with water vapour, leading to environmental hydrogen embrittlement of the alloys. The incorporation of Zr elements enhances the ductility of Ni3Al-Ni3V alloys, reduces the surface concentration of Al elements, and decreases the amount of H atoms produced by the reaction between Al and atmospheric moisture, thereby mitigating the environmental embrittlement phenomenon.
4) In the air environment, the surface of the alloy is oxidized under the action of air, accompanied by frictional wear, and the surface generates an Al2O3 oxide film to protect the workpiece; at this time, the friction coefficient and wear rate of the Ni3Al-Ni3V-Zr-Ni5Zr alloy are extremely low, and the main wear mechanisms in this environment are abrasive wear and oxidative wear; the oxide film generated on the surface in the O2 environment is very good at low loads When the oxide film reaches a certain thickness it becomes fragile and is prone to cracking or flaking. The flaking surface oxide particles plough through the alloy surface, increasing wear rates. The low O2 and water vapour content of the CO2 environment prevents the corresponding oxides from covering the surface and reducing wear; the main wear mechanism in the CO2 environment is abrasive wear.
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All Tables
Chemical composition (mole fraction) at each wear surface mark in Figs. 4 to 6 (unit:%)
Gibbs free energy of the reaction of the main elements of the alloy with water vapour
All Figures
Fig. 1 Microstructure and XRD patterns of Ni3Al-Ni3V and Ni3Al-Ni3V-Zr-Ni5Zr alloys (a) Ni3Al-Ni3V; (b) Ni3Al-Ni3V-Zr-Ni5Zr-Sample 1; (c) Ni3Al-Ni3V-Zr-Ni5Zr-Sample 2; (d) Ni3Al-Ni3V-Zr-Ni5Zr-Sample 3; (e) Ni5Zr-phase; (f) XRD of alloys |
|
In the text |
Fig. 2 Comparison of alloy friction coefficients (a) and wear rates (b) | |
In the text |
Fig. 3 Surface abrasion profile of Ni3Al-Ni3V alloy (a) 3 N; (b) 10 N; (c) 20 N; (d) Crackle |
|
In the text |
Fig. 4 Surface wear of alloys of Sample 1 (a)-(c): Air of 3, 10 and 20 N; (d)-(f): O2 of 3, 10 and 20 N; (g)-(i): CO2 of 3, 10 and 20 N |
|
In the text |
Fig. 5 Surface wear of alloys of Sample 2 in different atmospheres (a)-(c): Air of 3, 10 and 20 N; (d)-(f): O2 of 3, 10 and 20 N; (g)-(i): CO2 of 3, 10 and 20 N |
|
In the text |
Fig. 6 Surface wear of the alloy of Sample 3 in different atmospheres (a)-(c): Air of 3, 10 and 20 N; (d)-(f): O2 of 3, 10 and 20 N; (g)-(i): CO2 of 3, 10 and 20 N |
|
In the text |
Fig. 7 Mechanisms for the formation of alloy oxide films | |
In the text |
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