15 Wear

WEAR AND WEAR MECHANISMS
Wear
Wear is a process of removal of material from one or both of two solid surfaces in
solid state contact, occurring when these two solid surfaces are in sliding or rolling
motion together. Bhushan and Gupta (1991)
Wear is the progressive damage, involving material loss, which occurs on the surface
of a component as result of its motion relative to the adjacent working parts.
John Williams
Defining wear
Removal of material from operating solid surface by
◦ Solid –
 Load , velocity, environment, Materials
◦ Fluid–
 Velocity, pressure, Environment, Materials
Wear Increases:
1. Power loss
2. Oil consumption
3. Rate of component replacement.
Occurrence of Wear depends on
• Geometry of the surface
• Applied load
• The rolling and sliding velocities
• Environmental conditions
• Mechanical,Thermal, Chemical and Metallurgical properties
• Physical,Thermal and Chemical properties of the lubricant

Types of wear process
Abrasive wear
Abrasive wear occurs when a harder material is rubbing against a softer material
Two body wear
Three body
wear
𝑁𝐿
V = 𝐾 3σ𝑠
Where
V = wear volume, L = sliding velocity
N = applied load, σs = surface strength
K = wear coefficient
Types of abrasive wear
Gouging abrasion
• Large particles
• High compression loads
High stress or grinding abrasion

• Smaller particles
• High compression load
Low stress or scratching abrasion

• No compression load
• Scratching abrasion while material is sliding
Polishing abrasion
Ref.: www. mesto.com

Abrasive Wear
Abrasive wear observed on polymeric components

from retrieved spine implants, implanted 1.1 years.
Erosive wear
The impingement of solid particles, or small drops of liquid or gas on the solid
surface cause wear what is known as erosion of materials and components.
Pressure generated due to change in velocity
P = 𝞓V 𝐸𝞺
P = Impact pressure
E = Modulus of elasticity of impacted material
𝞺 = Density of the fluid
V = Velocity
Advantages
• Cutting, drilling and polishing of brittle

material
Ref.: dcu.ie/~stokesjt/Thermal Spraying/Book/Chapter1

Types of erosion
Solid particle erosion

Surface wear by impingement of solid particles carried by a gas or fluid.
e.g. Wear of helicopter blade leading edges in dusty environments.
• Liquid drop erosion

Surface wear by impingement of liquid drops.
e.g.Wear of centrifugal gas compressor blades by condensate droplets.
• Cavitation erosion
Surface wear in a flowing liquid by the generation and implosive collapse of
gas bubbles.
e.g. Fluid-handling machines as marine propellers, dam slipways, gates, and

all other hydraulic turbines.
Cavitation wear
 Cavitation is the formation of
vapour cavities in a liquid – i.e.
small liquid-free zones ("bubbles"
or "voids") – that are the
consequence of forces acting upon
the liquid.
 Cavitation, i.e., formation of

bubbles from a gas dissolved in the
blood, in patients with mechanical
prosthetic cardiac valves is a well-
known phenomenon[3]
Frictional wear / adhesive wear
Two bodies sliding over or pressed into each other which promote the material
transfer from one to another.
𝑉 𝑃
=𝐾
𝐿 3σ𝑦
Where
V = wear volume
L = sliding velocity
P = applied load Ref.: www.substech.com
σy = yield stress of softer material
K = wear coefficient
Adhesive wear
Adhesive wear is the transfer of material from one
contacting surface to another[2].
Mild adhesion — is the removal of surface films,

such as oxides, at a low rate.
Machine surface damaged by adhesive wear

Surface fatigue
• Two surfaces contacting to each other under

pure rolling, or rolling with a small amount of
sliding in contact
Contact fatigue
• As one element rolls many times
over the other element
• Maximum shear stress is higher
than fatigue limit
For cylinder
𝑃𝐸𝑒
τ𝑚𝑎𝑥=0.127 𝐿𝑅𝑒
𝑃𝑅𝑒
Z= 0.84 𝐿𝐸𝑒
For sphere
3 𝑃
τmax = 0.4 2 𝐸𝑒 2
𝑅
Ref.:W.A. Glaeser and S.J. Shaffer, Battelle Laboratories
3 𝑅𝑒
Z = 0.56 𝑃 𝐸𝑒
Delamination wear
A wear process where a material loss from the surface by forces of another
surface acting on it in a sliding motion in the form of thin sheets.
Mechanisms of delamination wear
• Plastic deformation of the surface

• Cracks are nucleated below
the surface
• Crack propagation from these
nucleated cracks and joining with
neighbouring one
• After separation from the surface,
laminates form wear debris
Ref.: K Kato, M Bai, N Umehara,Y Miyake

MODES OF FRETTING WEAR
 The important factors are :-
(a) Amplitude
(b) No. of cycles
(c) Frequency
(d) Material
(e) Contact temperature
(f) Stress field
(g) Environment
Chemical wear
Environmental conditions produce a reaction product on one or both of rubbing

surface and this chemical product is subsequently removed by the rubbing action.
Methods for control of the wear
• Lubrication technology
• Materials substitution
• Load reduction
• Removal of impact conditions
Corrosive wear
 Chemical reaction + Mechanical action =
Corrosive wear
Jaw coupling.
References
• Effect of internal stress of CNx coating on its wear in sliding friction - K Kato, M
Bai, N Umehara,Y Miyake
• TRIBOLOGY: THE SCIENCE OF COMBATTING WEAR - William A Glaeser
(Member, STLE), Richard C Erickson (Member, STLE), Keith F Dufrane (Member,
STLE) and
Jerrold W Kannel Battelle Columbus, Ohio
• Classification of wear mechanisms/models - K Kato
• www.rermwiki.com
• W.A. Glaeser and S.J. Shaffer, Battelle Laboratories
• www.substec.com
• Friction and lubrication in mechanical design – A.A. Seireg
• ocw.mit.edu/courses/mechanical-engineering/2-800-tribology
• dcu.ie/~stokesjt/Thermal Spraying/Book/Chapter1
• Wikipedia

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WEAR AND WEAR MECHANISMS

• Geometry of the surface

• The rolling and sliding velocities

• Mechanical,Thermal, Chemical and Metallurgical properties

• Physical,Thermal and Chemical properties of the lubricant

Two body wear

High stress or grinding abrasion

Low stress or scratching abrasion

Ref.: www. mesto.com

Abrasive wear observed on polymeric components

Pressure generated due to change in velocity

• Cutting, drilling and polishing of brittle

Ref.: dcu.ie/~stokesjt/Thermal Spraying/Book/Chapter1

Solid particle erosion

e.g. Wear of helicopter blade leading edges in dusty environments.

• Liquid drop erosion

e.g.Wear of centrifugal gas compressor blades by condensate droplets.

e.g. Fluid-handling machines as marine propellers, dam slipways, gates, and

 Cavitation, i.e., formation of

Mild adhesion — is the removal of surface films,

Machine surface damaged by adhesive wear

• Two surfaces contacting to each other under

Mechanisms of delamination wear

• Plastic deformation of the surface

Ref.: K Kato, M Bai, N Umehara,Y Miyake

Environmental conditions produce a reaction product on one or both of rubbing

Methods for control of the wear

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