VISVESHWARAYA TECHNOLOGICAL UNIVERSITY

BELGAUM

A Project Report On

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF

MILD STEEL COATED WITH INCONEL 718

Submitted By

Rajeeb Kumar Biswal 1DB06ME053

Smutesh Mishra 1DB06ME066

Snehanshu Mohan 1DB06ME067

Sourajit Banerjee 1DB06ME068

2009-10

DEPARTMENT OF MECHANICAL ENGINEERING

DON BOSCO INSTITUTE OF TECHNOLOGY

BANGALORE -560074

DON BOSCO INSTITUTE OF TECHNOLOGY

KUMBALAGUDU, MYSORE ROAD

BANGALORE-74

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the project work entitled STUDY OF “DRY SLIDING WEAR

BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718” carried out by

Mr. Rajeeb Kumar Biswal, Smutesh Mishra, Snehanshu Mohan and Sourajit

Banerjee USN 1DB06ME053, 1DB06ME066, 1DB06ME067 and 1DB06ME068, are

bonafide students of Don Bosco Institute of Technology, in partial fulfillment for the

award of Bachelor of Engineering in Mechanical Engineering of the Visveswaraya

Technological University, Belgaum during the year 2009-2010. It is certified that all

corrections/suggestions indicated for Internal Assessment have been incorporated in the

Report deposited in the departmental library. The project report has been approved as it

satisfies the academic requirements in respect of Project work prescribed for the said

Degree.

Name & Signature Name & Signature Signature of the

of the Guide of the HOD Principal

(Prof. R.Suresh Kumar) (Prof. A R K Swamy) (Dr. K.Muralidhar)

External Viva

Name of the examiners Signature with date

1)

2)

I

ABSTRACT

Tribological studies are gaining importance in the present day world where

machinery with high speeds is a trend.

Steel is the material of present day world where almost every component contains an

element of steel. Mild steel is widely used in the fields of automobile, aero-space,

domestic use, etc.

Friction in rubbing surfaces causes wear and loss of energy. One way of improving

surface resistance to wear is by applying coatings.

In the present work, mild steel is coated with Inconel 718 and studied for dry sliding

wear behavior.

II

ACKNOWLEDGMENT

Before introducing our project work, we would like to thank the people without

whom the success of this project could have not been possible.

We express our deep sense of gratitude to R.SURESHKUMAR., M.Tech Asst

Professor Mechanical Engineering Department, Don Bosco Institute of Technology, for

his valuable guidance, continuous assistance, and encouragement throughout the project

and in the critical appraisal of the manuscript.

We express our sincere thanks to A.R.K.SWAMY, Professor and HOD,

Department of mechanical Engineering, Don Bosco Institute of Technology, for

providing the facilities required for the completion of this project work.

It is with great pleasure; we extend our gratitude and special thanks to

Dr. K.MURALIDHAR, Principal, Don Bosco Institute of Technology, for permitting us

to carryout this project work.

We our extremely grateful to all the teaching and non-teaching staff of mechanical

engineering Department for their valuable suggestions and extending help and co-

operation whenever needed.

We feel short of words to express our heartfelt thanks to all my family members

and friends and all those who have directly or indirectly helped us to complete this work.

III

TABLE OF CONTENTS

SL. NO. DESCRIPTION PAGE NO.

CHAPTER 1 PREAMBLE 1

1.1 Introduction………………………………………………………...… 2

1.2 Problem definition...…………………………………………………..2

1.3 Methodology………………………………………………………......3

CHAPTER 2 LITERATURE SURVEY 4

2.1 Classification of coating……………………………………………….5

2.2 Advantages of coating ………………………..………….…................6

2.3 General description of thermal spraying ………………….............. …6

2.4 Thermal spray processes ………….……………………….………….7

2.4.1Plasma spraying …………….……………………...…...........7

2.4.2 Working process …………………………………...…..........7

2.4.3 Plasma spray deposition.…………………………...…..........9

2.4.4 Application…... …………………………………...….........10

2.5 Bonding ………………………………………………….……..........10

2.5.1 Surface preparation for thermal spray coatings……………12

2.5.2 Thermal spray coating bonding mechanisms………………12

2.5.3 Factors effecting bonding and subsequent build up of the

Coatings……………………………………………………13

2.6Mild steel……….. ……………………………………………...........14

2.6.1 Properties of mild steel ………………………....…………14

2.6.2 Physical properties of mild steel …………………………..15

2.6.3 Typical applications of mild steel …………………………16

2.7 Inconel………………………………………………………..............16

2.21.1 Composition of Inconel ………………………..…...........17

2.21.2 Types of Inconel ………………………………...……….18

2.8 Inconel 718…………………………………………………..............20

2.8.1 Composition …………..………………………..….............20

2.8.2 Physical properties ……………………………...………...21

2.8.3 Mechanical properties …………………………….............22

2.8.4 Application……….……………………………...…………22

IV

2.9 Wear…….…………………………………………………...............22

2.9.1 Adhesive wear……………………………………………...23

2.9.2 Abrasive wear…..:……………………………...…………24

2.9.3 Erosive wear ……….……………………………...............25

2.9.4 Surface fatigue ……….………………………....…………26

2.9.5 Fretting wear ……………………………………...............27

2.9.4 Corrosive wear ……….………………………....………..28

2.10 Review of International Published Paper…………………………29

2.10.1 Study of Dry Sliding Wear of Plasma Sprayed

Mo-Ni/Cr - Ti-6Al-4V Tribo Pair………………...........29

2.10.2 Dry sliding wear characteristicsof 0.13 wt. %

carbon steel……………………………………………..29

2.10.3 Dry sliding wear behavior of Al 2219/SiC metal matrix

composites……………………………………………….30

2.10.4 Friction and wear characteristic of ductile iron in

dry sliding conditions……..…………………………….30

2.10.5 Tribochemistry in sliding wear of TiCN–Ni-based

Cermets…………………………………………………31

CHAPTER 3 EXPERIMENTAL DETAILS……………………….32

3.1 Stages Involved..……………………………………………………33

3.2 Surface preparation before coating …………………………………33

3.3 plasma spraying technique ..…………………………………………33

3.4 Specimens for testing …..……………………………………………35

3.5 Measurement of wear rate using pin-on-disc wear testing machine

(tribometer)………………………………………………………………36

3.5.1 Apparatus Used…….. ……………………………………38

3.5.2 Material Used……………...………………………............38

3.5.3 Procedure…………………. ………………………………38

CHAPTER-4 RESULTS & DISCUSSION…………………...........39

4.1 Evaluating of wear rate using Pin-On-Disc wear tester…………….40

4.2 Graphs…………………………………………... ……………….…61

CHAPTER-5 CONCLUSION………………… ..…………………73

CHAPTER-6 SCOPE FOR FUTURE…………. .…………...........75

REFERENCES …………………………………………………….........77

V

LIST OF TABLES

SL. NO. DESCRIPTION PAGE NO.

Table.2.1 Physical properties of Mild Steel 15

Table 2.2 Mechanical properties of Mild steel 15

Table 2.3 Composition of Inconel 17

Table 2.4 Composition of Inconel 718 21

Table 2.5 Physical prorperties 22

Table 3.1 Specification of plasma spray coatings 34

Table 3.2 Specification of a Tribometer 37

Table 4.1 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm

and Load: 10N) 41

Table 4.2 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm

and Load: 20N) 42

Table 4.3 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm

and Load: 30N) 43

Table 4.4 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm

and Load: 40N) 44

Table 4.5 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm

and Load: 50N) 45

Table 4.6 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm

and Load: 10N) 46

Table 4.7 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm

and Load: 20N) 47

Table 4.8 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm

and Load: 30N) 48

Table 4.9 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm

and Load: 40N) 49

Table 4.10 (UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm

and Load: 50N) 50

Table 4.11 (COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and

Load: 10N) 51

VI

Table 4.12 (COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm

and Load: 20N) 52

Table 4.13 (COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and

Load: 30N) 53

Table 4.14 (COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and

Load: 40N) 54

Table 4.15 (COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and

Load: 50N) 55

Table 4.16 (COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and

Load: 10N) 56

Table 4.17 (COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and

Load: 20N) 57

Table 4.18 (COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and

Load: 30N) 58

Table 4.19 (COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and

Load: 40N) 59

Table 4.20 (COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and

Load: 50N) 60

VII

LIST OF FIGURES

Sl. NO. DESCRIPTION PAGE NO.

Figure 2.1 Plasma Spray Process 7

Figure 2.2 Plasma Spray Process 8

Figure 2.3 Plasma Spray Deposition 9

Figure 2.4 Schematic diagram of thermally sprayed spherical particle impinged onto a

flat substrate 11

Figure 2.5 Schematic Diagram of Thermal Spray Metal Coating 12

Figure 2.6 Microstructure of a metallic thermally sprayed coating 13

Figure 2.7: Mild steel square 14

Figure 2.8: Inconel 718 (Microscopic view) 20

Figure 2.9: Adhesive wear 24

Figure 2.10: Abrasive wear 25

Figure 2.11 Erosive wear 26

Figure 2.12: Surface fatigue 27

Figure 2.13: Schematic fretting wear 27

Figure 2.14: Schematic corrosive wear 28

Figure 3.1 Side view of spray gun 34

Figure 3.2 Front view of spray gun 34

Figure 3.3 Mixing chamber 35

Figure 3.4 Plasma spray controls 35

Figure 3.5 Uncoated sample 35

Figure 3.6 Coated sample 35

Figure 3.7 Principle behind a Tribometer 36

Figure 3.8 Tribometer 37

Figure 3.9 Pin-on-disc machine’s digital display 38

Figure 3.10 Digital weighing machine 38

Figure 4.1 Wear v/s load at 300rpm 61

Figure 4.2 Wear v/s load at 500rpm 61

Figure 4.3 COF v/s load at 300rpm 62

Figure 4.4 COF v/s load at 300rpm 62

Figure 4.5 Wear v/s Sliding distance at 10N & 300rpm 63

Figure 4.6 Wear v/s Sliding distance at 20N & 300rpm 63

VIII

Figure 4.7 Wear v/s Sliding distance at 30N & 300rpm 64

Figure 4.8 Wear v/s Sliding distance at 40N & 300rpm 64

Figure 4.9 Wear v/s Sliding distance at 50N & 300rpm 65

Figure 4.10 Wear v/s Sliding distance at 10N & 500rpm 65

Figure 4.11 Wear v/s Sliding distance at 20N & 500rpm 66

Figure 4.12 Wear v/s Sliding distance at 30N & 500rpm 66

Figure 4.13 Wear v/s Sliding distance at 40N & 500rpm 67

Figure 4.14 Wear v/s Sliding distance at 50N & 500rpm 67

Figure 4.15 Wear v/s Sliding distance at 10N & 300rpm 68

Figure 4.16 Wear v/s Sliding distance at 20N & 300rpm 68

Figure 4.17 Wear v/s Sliding distance at 30N & 300rpm 69

Figure 4.18 Wear v/s Sliding distance at 40N & 300rpm 69

Figure 4.19 Wear v/s Sliding distance at 50N & 300rpm 70

Figure 4.20 Wear v/s Sliding distance at 10N & 500rpm 70

Figure 4.21 Wear v/s Sliding distance at 20N & 500rpm 71

Figure 4.22 Wear v/s Sliding distance at 30N & 500rpm 71

Figure 4.23 Wear v/s Sliding distance at 40N & 500rpm 71

Figure 4.24 Wear v/s Sliding distance at 50N & 500rpm 71

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH

INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 1

CHAPTER 1

PREAMBLE

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH

INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 2

CHAPTER 1

PREAMBLE

1.1 INTRODUCTION:

Mild steel is one of the most common metals which find its application in

fabrication, manufacturing processes and all other metal removal processes. During metal

removal processes since mild steel is used as the cutting metal it inevitably makes contact

with the work piece and other metal surfaces resulting in wear and subsequently reducing

the life and efficiency of the tool. To enhance life of these parts, their mechanical and

tribological properties should be improved. Improvement of the properties can be

accomplished in two methods. One is by reinforcing the metal parts with metal

composites and second best method is to coat these surfaces with other hard substances.

Coating is a covering that is applied to the surface of an object, usually referred to

as the substrate. In many cases coatings are applied to improve surface properties of the

substrate, such as appearance, adhesion, weld-ability, corrosion resistance, wear

resistance, and scratch resistance. Coatings may be applied as liquids, gases or solids. The

material on which these coatings are applied is called substrate. Thermal spraying is a

method of coating.

Another method of coating the material is by Plasma spraying technique using a

plasma jet. Deposits having thickness from micrometers to several millimeters can be

produced from a variety of materials - metals, ceramics, polymers and composites.

In this project, we would study the dry sliding wear behavior of mild steel coated

with Inconel 718. Inconel alloy 718 has been used widely in the aviation, space

navigation and shipping industries because of its outstanding multi-properties. In our

project work, Mild steel has been coated with Inconel 718 alloy using plasma spray

technique and would be tested for various parameters by varying the load and keeping

speed and track radius constant.

1.2 PROBLEM DEFINITION:

Mild Steel and its alloys are finding enormous applications in the field of

automobile engineering for manufacturing of axles, crankshafts, steering, steering shaft,

levers, aircrafts and heavy vehicle components and building constructions.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH

INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 3

During working, there is always a relative motion and friction between the metal

parts resulting in wear and tear. Due to this many adverse effects will be encountered by

the specimen which renders loss of material, excess consumption of power during

working, shift in the tolerances, wiping of lubrication etc. To make mild steel further

versatile and flexible for various application and to provide a long life under different

environments coatings are applied which provide better service and better quality to the

metal pieces.

Since all the manufacturing and fabrication processes involve the use of mild steel

as the metal removal agent a method has to be adopted to minimize the wear of the Mild

Steel and improve its shelf life.

In order to enhance life of these parts, their mechanical properties and tribological

properties should be improved. This can be done by reinforcing the metal parts with metal

composites or by coating these surfaces with other hard substrates. If we go for

reinforcement it changes the material property itself as it is mixed with the base metal and

in case if only surface property has to be improved its better to go for coating as it

improves property only at surface. And also to avoid excessive cost incurred for

reinforcing the metal it’s feasible to go for coatings since friction is a surface

phenomenon.

Therefore in the present investigation, a comparative study had been conducted to

evaluate the various tribological properties such as wear. To enhance the tribological

properties of Mild Steel, it was decided to apply Inconel 718 coating on Mild Steel by

plasma spray coating and study its wear behavior by conducting dry sliding wear tests.

1.3 METHODOLOGY:

Step1: Test specimen will be first prepared to the given dimensions by various

machining process.

Step 2: The prepared specimen is to be coated with Inconel 718 by plasma

spraying machine.

Step 3: To carry out dry sliding wear tests to assess their tribological properties

and behavior under working conditions in a Pin-On-Disc Machine.

Step4: Presentation of the test results in the form of tabular columns and graphs

with inference and conclusion along with illustrations.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 4

CHAPTER 2

LITERATURE

SURVEY

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 5

CHAPTER-2

COATING

Coating is a covering that is applied to the surface of an object, usually referred to

as the substrate. In many cases coatings are applied to improve surface properties of the

substrate, such as appearance, adhesion, weld-ability, corrosion resistance, wear

resistance and scratch resistance. In other cases, in particular in printing processes and

semiconductor device fabrication (where the substrate is a wafer), the coating forms an

essential part of the finished product.

2.1 CLASSIFICATION OF COATING:

COATING AND PRINTING PROCESSES: Coating and printing processes

involve the application of a thin film of functional material to a substrate, such as

roll of paper, fabric, film or other textile. The coating or printing can be applied to

serve some sort of function (e.g. water-proofing) or just for decoration.

CHEMICAL VAPOR DEPOSITION AND PHYSICAL VAPOUR

DEPOSITION : Chemical vapor deposition (CVD) is a chemical process used to

produce high-purity, high-performance solid materials. The process is often used

in the semiconductor industry to produce thin films. In a typical CVD process, the

wafer (substrate) is exposed to one or more volatile precursors, which react and/or

decompose on the substrate surface to produce the desired deposit.

PICKLING: Pickling is a treatment of metallic surfaces in order to remove

impurities, stains, rust or scale with a solution called pickle liquor, containing

strong mineral acids, before subsequent processing, such as extrusion, rolling,

painting, galvanizing or plating with tin or chromium. The two acids commonly

used are hydrochloric acid and sulfuric acid. Pickling liquor may be a combination

of acids and may also contain nitric or hydrofluoric acids.

PLATING: Plating describes surface-covering where a metal is deposited on a

conductive surface. Plating has been done for hundreds of years, but it is also

critical for modern technology. Plating is used to decorate objects, for corrosion

inhibition, to improve solder ability, to harden, to improve wear ability, to reduce

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 6

friction, to improve paint adhesion, to alter conductivity, for radiation shielding,

and for other purposes.

POLYMER COATINGS:A polymer is a substance composed of molecules with

large molecular mass composed of repeating structural units, or monomers,

connected by covalent chemical bonds

2.2 ADVANTAGES OF COATING:

Coatings emit zero or near zero volatile organic compounds (VOC).

Coating overspray can be recycled and thus it is possible to achieve nearly 100%

use of the coating.

Coating production lines produce less hazardous waste .

Capital for equipment and operating costs for a powder line are generally less.

Coated items generally have fewer appearance differences between horizontally

coated surfaces and vertically coated surfaces than liquid coated items.

A wide range of specialty effects is easily accomplished which would be

impossible to achieve with other coating processes.

2.3 GENERAL DESCRIPTION OF THERMAL

SPRAYING:

Thermal spraying is a group of processes wherein a feedstock material is heated

and propelled as individual particles or droplets onto a surface. The thermal spray gun

generates the necessary heat by using combustible gases or an electric arc. As the

materials are heated, they are changed to a plastic or molten state and are confined and

accelerated by a compressed gas stream to the substrate. The particles strike the substrate,

flatten, and form thin platelets (splats) that conform and adhere to the irregularities of the

prepared substrate and to each other. As the sprayed particles impinge upon the surface,

they cool and build up, splat by splat, into a laminar structure forming the thermal spray

coating. The coating that is formed is not homogenous and typically contains a certain

degree of porosity, and, in the case of sprayed metals, the coating will contain oxides of

the metal. Feedstock material may be any substance that can be melted, including metals,

metallic compounds, cements, oxides, glasses, and polymers. Feedstock materials can be

sprayed as powders, wires, or rods. The bond between the substrate and the coating may

be mechanical, chemical, or metallurgical or a combination of these. The properties of the

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 7

applied coatings are dependent on the feedstock material, the thermal spray process and

application parameters, and post treatment of the applied coating.

2.4 THERMAL SPRAY PROCESSES:

Thermal spray processes may be categorized as either combustion or electric

processes. Combustion processes include flame spraying, HVOC spraying, and

detonation flame spraying. Electric processes include arc spraying and plasma spraying.

2.4.1 PLASMA SPRAY:

Plasma spraying is used to apply surfacing materials that melt at very high

temperatures. An arc is formed between an electrode and the spray nozzle, which acts as

the second electrode. A pressurized inert gas is passed between the electrodes where it is

heated to very high temperatures to form a plasma gas. Powdered feedstock material is

then introduced into the heated gas where it melts and is propelled to the substrate at a

high velocity. A plasma spray system consists of a power supply, gas source, gun, and

powder feeding mechanism. Plasma spraying is primarily performed in fabrication shops.

The Plasma Spray Process is basically the spraying of molten or heat softened

material onto a surface to provide a coating. Material in the form of powder is injected

into a very high temperature plasma flame, where it is rapidly heated and accelerated to a

high velocity. The hot material impacts on the substrate surface and rapidly cools forming

a coating. This plasma spray process carried out correctly is called a "cold process"

(relative to the substrate material being coated) as the substrate temperature can be kept

low during processing avoiding damage, metallurgical changes and distortion to the

substrate material.

Fig 2.1 Plasma Spray Process

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 8

2.4.2 WORKING PROCESS:

The plasma spray gun comprises a copper anode and tungsten cathode, both of

which are water cooled. Plasma gas (argon, nitrogen, hydrogen, helium) flows around the

cathode and through the anode which is shaped as a constricting nozzle. The plasma is

initiated by a high voltage discharge which causes localised ionisation and a conductive

path for a DC arc to form between cathode and anode. The resistance heating from the arc

causes the gas to reach extreme temperatures, dissociate and ionise to form a plasma. The

plasma exits the anode nozzle as a free or neutral plasma flame (plasma which does not

carry electric current) which is quite different to the Plasma Transferred Arc coating

process where the arc extends to the surface to be coated. When the plasma is stabilised

ready for spraying the electric arc extends down the nozzle, instead of shorting out to the

nearest edge of the anode nozzle. This stretching of the arc is due to a thermal pinch

effect. Cold gas around the surface of the water cooled anode nozzle being electrically

non-conductive constricts the plasma arc, raising its temperature and velocity. Powder is

fed into the plasma flame most commonly via an external powder port mounted near the

anode nozzle exit. The powder is so rapidly heated and accelerated that spray distances

can be in the order of 25 to 150 mm.

The plasma spray process is most commonly used in normal atmospheric

conditions and referred as APS. Some plasma spraying is conducted in protective

environments using vacuum chambers normally back filled with a protective gas at low

pressure, this is referred as VPS or LPPS.

Fig 2.2:Plasma Spray Process

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 9

Plasma spraying has the advantage that it can spray very high melting point materials

such as refractory metals like tungsten and ceramics like zirconia unlike combustion

processes. Plasma sprayed coatings are generally much denser, stronger and cleaner than

the other thermal spray processes with the exception of HVOF and detonation processes.

Plasma spray coatings probably account for the widest range of thermal spray coatings

and applications and makes this process the most versatile.

Disadvantages of the plasma spray process are relative high cost and complexity of

process.

2.4.3 PLASMA SPRAY DEPOSITION:

In the Plasma Spraying Process powder is softened or melted in the plasma gas

stream, which also transfers the particles to the work piece. The plasma arc is not

transferred to the work piece, it is contained within the plasma torch between an axial

electrode and a water cooled nozzle. The process is operated in normal atmosphere,

in a shielding gas stream (e.g. Argon), in a vacuum or under water. Due to the high

temperature of the plasma gas stream the Plasma process is especially suitable for

spraying high melting point metals as well as their oxides and carbides.Benefits of

Plasma Spraying are: Operates In Several Environments Ideal for High Melting Point

Materials

Fig 2.3:Plasma Spray Deposition

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 10

2.4.4 APPLICATIONS:

Textiles

Petrochemical and chemicals

Steel

Paper pulp and printing machinery

Thermal power plants

Oil and natural gas industries

Automotive

Glass

Medical

2.5 BONDING:

Coatings applied using thermal spray processes typically depend on a mechanical

(interlocking) bond. The nature of the substrate surface is therefore a key to quality

Thermal Spray Coatings. For successful coatings, the substrate surface needs to rough

and pitted to provide a “foot-hold” (Splat-Hold) for each splat of powder that impacts the

substrate. In addition, the surface needs to be clean and free from contamination that

would fill the pits and prevent locking of the splats. How is this achieved?

Grit blasting is popular for surface preparation, which is simply pressurizing an

abrasive media with compressed air and aiming the stream of accelerated particles at the

surface being prepared. Many are familiar with grit blasting for cleaning surfaces prior to

painting. However, grit blasting for thermal spray is quite different since more than

removal of oxides is needed; instead, pits and crevices need to be formed where the

molten thermal spray particles “splat” into the rough surface and adhere.

Grit blasting in preparation for thermal spray depends on dry abrasives. The grit

blast material should be sharp and angular so that it will cut into the substrate on

impact. It is also beneficial if it produces under-cut pits for a strong mechanical

bond. The need for sharp, angular grit is the reason that grit for Thermal Spray operations

needs to be changed-out more often than the grit used for surface cleaning

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 11

operations. The most common materials used for grit blast is aluminum oxide and chilled

iron. The typical; surface finish after grit blast is anywhere from 15 RMS to

100RMS. The variables that will affect the final finish include media size, media

morphology, media hardness, air pressure, distance from the work piece, angle of

impingement, and anything that will affect the speed of the media hitting the work piece.

The substrate is physically deformed during grit blast operations resulting in residual

stresses being formed on the surface. This is easily demonstrated by grit blasting a thin

strip of test material, often called an almen strip, and observing how the metal

“bows”. This is due to the higher residual stress that is created on one side of the strip

being grit blasted. “Shot-peening” has the opposite effect of reducing residual stress on

the surface.

In summary, Grit Blast operations for Thermal Spray need to be properly used and

controlled to provide a consistently strong bond by providing the proper splat pits for the

coating material.

Fig 2.4 Schematic diagram of thermally sprayed spherical particle impinged onto a

flat substrate

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 12

2.5.1 SURFACE PREPARATION FOR THERMAL SPRAY

COATINGS:

An essential feature of any coating system is the bond between the coating and the

substrate. Thermal Spray operations are typically based on the materials being applied to

the substrate in the plastic (non-molten) state. Therefore, the bond is not due to fusion

between the coating and the substrate. In addition, there is usually little or no chemical

reaction between the coating and the substrate, so the bond is not chemical in nature

2.5.2 THERMAL SPRAY COATING BONDING MECHANISMS:

Mechanical keying or interlocking.

Diffusion bonding or Metallurgical bonding.

Other adhesive, chemical and physical bonding mechanisms -oxide films, Van der

Waals forces etc.

Fig2.5 Schematic Diagram of Thermal Spray Metal Coating

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2.5.3 FACTORS EFFECTING BONDING AND SUBSEQUENT BUILD

UP OF THE COATING:

Cleanliness

Surface area

Surface topography or profile

Temperature ( thermal energy )

Time (reaction rates & cooling rates etc.)

Velocity ( kinetic energy )

Physical & chemical properties

Physical & chemical reactions.

Cleaning and grit blasting are important for substrate preparation. This provides a more

chemically and physically active surface needed for good bonding. The surface area is

increased which will increase the coating bond strength. The rough surface profile will

promote mechanical keying.

Fig 2.6- A typical microstructure of a metallic thermally sprayed coating. The

lamellar structure is interspersed with oxide inclusions and porosity.

High kinetic energy thermal spraying using HEP, HVOF and cold spray produce high

bond strengths due to the energy liberated from high velocity impacts. The high density

tungsten carbide/cobalt and cold spray coatings are good examples.

Metallurgical or diffusion bonding occurs on a limited scale and to a very limited

thickness (0.5 µm max. with heat affected zone @ 25µm) with the above type coatings.

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Fused coatings are different. These are re-melted and completely metallurgically bonded

with the substrate and it’s self.

2.6 MILD STEEL:

Mild steel is a carbon steel typically with a maximum of 0.25% Carbon and 0.4%-

0.7% manganese, 0.1%-0.5% Silicon and some traces of other elements such as

phosphorous, it may also contain lead (free cutting mild steel) or sulphur (again free

cutting steel called re-sulphurised mild steel)

Fig 2.7 Mild steel square

2.6.1 PROPERTIES OF MILD STEEL:

Mild Steel is an alloy with carbon, manganese, Nickel, silicon and balance is iron

as the alloying elements. It has generally good mechanical properties and is heat treatable

and weld able. It is one of the most common alloys of mild steel for general purpose use.

Typical properties of Mild Steel include:

Medium to high strength

Good toughness

Good surface finish

Excellent corrosion resistance to atmospheric conditions

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Good corrosion resistance to sea water

Can be anodized

Good weldability and brazability

Good workability

Widely available.

2.6.2 PHYSICAL PROPERTIES OF MILD STEEL:

PARTICULARS UNITS

Density 8.19 g/cm3

Melting Point/Range 1260 - 1336 deg c

Specific Heat: 435 J/kg · K

Average Coefficient of Thermal Expansion 13.0 μm/m · K

Thermal Conductivity 11.4 W/m · K

Electrical Resistivity 1250 n · m

Curie Temperature -112 deg C

Table 2.1-Physical properties of Mild Steel

Table 2.2-Mechanical properties of Mild steel

PARTICULARS UNITS

Ultimate Tensile Strength 1240 MPa

Yield Strength 1036 MPa

Elongation in Elastic Modulus Strength (0.2

% offset) 50 mm (2")

12 %

Elastic Modulus (Tension) 211 GPa

Hardness 36 HRC

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2.6.3 TYPICAL APPLICATIONS OF MILD STEEL:

Heavy Vehicles components.

Marine fittings.

Large modern structures, such as stadiums, skyscrapers and Airports.

Building constructions.

Flyover and Bridge constructions.

Heat treated gun parts

Nuts, Bolts and Kick-Starts.

Joints and Channels.

Angle bolts, Rivets, and Sheets.

Brake components.

Automobile components like

i) Axles.

ii) Crankshafts.

iii) Connecting Rod.

2.7 INCONEL:

Inconel is a registered trademark of Special Metals Corporation that refers to a

family of austenitic nickel-chromium-based superalloys. Inconel alloys are typically used

in high temperature applications. It is often referred to in English as "Inco" (or

occasionally "Iconel"). Common trade names for Inconel include: Inconel 625, Chronin

625, Altemp 625, Haynes 625, Nickelvac 625 and Nicrofer 6020.Inconel alloys are

generally known for their resistance to oxidation and their ability to maintain their

structural integrity in high temperature atmospheres. There are several Inconel alloys that

are used in applications that require a material that does not easily succumb to caustic

corrosion, corrosion caused by high purity water, and stress-corrosion cracking. While

each variation of Inconel has unique traits that make it effective in different

circumstances, the majority of the alloys are used frequently in the chemical industry.

Inconel 601 is a nickel-chromium alloy that has additions of aluminum. These additions

increase its resistance to oxidation and various forms of corrosion. This has made Inconel

601 a common material in heat treating equipment, furnaces, and gas-turbine components.

Inconel 690 has a similar makeup to 601, but it is considered a high chromium-nickel

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alloy. The high chromium content in 690 makes it especially resistant to corrosion that

occurs from salts, oxidizing acids, and other elements commonly found in aqueous

environments. Inconel 625 differs from many of the other Inconel alloys because its

composition includes substantial amounts of nickel, chromium, and molybdenum. It also

has an addition of niobium. The result is an alloy that possesses high levels of strength

without ever having to go through a strengthening heat treatment. Inconel 625 is

especially effective at resisting crevice corrosion, making it a chosen material in the

aerospace and marine engineering industries.

2.7.1 COMPOSITION OF INCONEL:

Different Inconels have widely varying compositions, but all are predominantly

nickel, with chromium as the second element

Inconel

Element (% by mass)

Nic

kel

Ch

rom

ium

Iron

Moly

bd

enu

m

Nio

biu

m

Cob

alt

Man

gan

ese

Cop

per

Alu

min

ium

Tit

an

ium

Sil

icon

Carb

on

Su

lfu

r

Ph

osp

horu

s

Boro

n

600

72.0

14.0

-

17.0

6.0

-10.0

1.0

0.5

0.5

0.1

5

0.0

15

- -

625

58.0

20.0

-

23.0

5.0

8.0

-10.0

3.1

5-

4.1

5

1.0

0.5

0.4

0.4

0.5

0.1

0.0

15

0.0

15

-

718

50.0

-55.0

17.0

-21.0

bal

ance

2.8

-3.3

4.7

5-5

.5

1.0

0.3

5

0.2

-0.8

0.6

5-1

.15

0.3

0.3

5

0.0

8

0.0

15

0.0

15

0.0

06

Table 2.3- Composition of Inconel

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2.7.2 TYPES OF INCONEL:

INCONEL 600:

Inconel 600 is a nickel-chromium alloy that offers high levels of resistance to a

number of corrosive elements. In high-temperature situations, Inconel 600 will not

succumb to chloride-ion stress-corrosion cracking or general oxidation. The alloy is also

resistant to caustic corrosion and corrosion caused by high purity water.

Its ability to withstand corrosion in a variety of forms has made Inconel 600 the perfect

alloy for use in furnace components and chemical processing equipment. However,

Inconel 600 is also used effectively in the food industry and in nuclear engineering,

because it will maintain its structure in applications that would cause permanent,

irreversible distortion to other alloys.

INCONEL 601:

Like Inconel 600, Inconel 601 offers resistance to various forms of high-

temperature corrosion and oxidization. However, unlike 600, this nickel-chromium alloy

has an addition of aluminum. This addition allows it to demonstrate high mechanical

properties even in extremely hot environments.

Inconel 601's ability to stave off the strain that would result in many alloys when exposed

to high temperatures has led to its use in furnaces and heat treating equipment like retorts

and baskets. You will also find Inconel 601 in gas-turbine components and petrochemical

processing equipment.

INCONEL 625:

Inconel 625 is the rare alloy that gains strength without having to undergo an

extensive strengthening heat treatment. Inconel 625 is a nickel-chromium-molybdenum

alloy with an addition of niobium. The niobium reacts with the molybdenum, causing the

alloy's matrix to stiffen and increasing its strength level.

Like most Inconel alloys, Inconel 625 has high resistance to a number of corrosive

elements. In fact, it can withstand harsh environments that would all but destroy other

alloys. It is particularly effective when it comes to staving off crevice corrosion and

pitting. Inconel 625 is a versatile alloy that requires less work than most. It is effectively

used in the aerospace industry, marine engineering, the chemical and energy industries,

and much more.

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INCONEL 690:

The Inconel alloys consist mainly of a group of metal alloys that offer high

resistance to corrosive materials and environments. Inconel 690 falls into this category.

However, unlike some of the other alloys in the group, it is a high-chromium and nickel

alloy. The high-chromium element of the alloy gives it a particularly strong resistance to

corrosion that occurs in aqueous atmospheres. Generally, this corrosion occurs as

oxidizing acids and salts break a material down. Along with its ability to resist these

stresses, Inconel 690 can also withstand the sulfidation that takes place at extremely high

temperatures. Along with its resistance to corrosives, Inconel 690 possesses strong

metallurgical stability which allows it to maintain structural integrity in a wide range of

applications. It also has a high level of strength and possesses fabrication traits that enable

it to be used in a number of different settings. All of these aspects of Inconel 690 have

made it a versatile alloy that has found use in a range of industries.

INCONEL 718:

Inconel 718 possesses the resistance to corrosive elements that are common

among Inconel alloys. However, Inconel 718 differs from other alloys in its "family" in

structure and response. 718 is a precipitation-hardenable nickel-chromium alloy. It

contains substantial levels of iron, molybdenum, and niobium as well as trace amounts of

titanium and aluminum. Its makeup allows for an ease of welding that is not matched by

the majority of Inconel alloys. It also allows Inconel 718 to combine anti-corrosive

elements with a high level of strength and flexibility. Inconel 718 is particularly resistant

to post-weld cracking, and it can maintain its structure in both high-temperature and

aqueous environments. In fact, it will maintain superb creep-rupture strength at

temperatures as high as 1,300oF. The unique qualities of Inconel 718 have caused it to be

used in industries and applications where other Inconel alloys simply would not be

effective. You will find it in nuclear reactors, spacecraft, and rocket motors. However, it

does have more common applications, as well. It can be very effective in tooling and gas

turbines. There is also a version of the alloy (718 SPF) that is used specifically for super-

plastic forming.

INCONEL 722:

Inconel 722 is a nickel-chromium alloy that shares many of the same properties as

other Inconel alloys. It demonstrates a high level of resistance to various forms of

corrosion. It also has the capacity to remain effective at extremely high temperatures.

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Inconel 722 can withstand the stress caused by several types of acids, which has made it a

common metal in the chemical industry.

INCONEL 903

Inconel 903 is part of a family of alloys that are known for their resistance to

corrosion caused by a wide range of stresses in a variety of settings. Many Inconel alloys

can remain effective in high temperature and aqueous atmospheres. Most are resistant to

multiple acids, as well, so they are used regularly in the petrochemical industry.

2.8 INCONEL 718

Inconel 718 is a precipitation-hardenable nickel-chromium alloy containing

significant amounts of iron, niobium, and molybdenum along with lesser amounts of

aluminum and titanium. It combines corrosion resistance and high strength with

outstanding weldability, including resistance to postweld cracking. The alloy has

excellent creep-rupture strength at temperatures up to 700 oC (1300

oF). Used in gas

turbines, rocket motors, spacecraft, nuclear reactors, pumps, and tooling

.

Fig 2.8-Inconel 718 (Microscopic view)

.

2.8.1 COMPOSITION:

Inconel 718 is a nickel-based super alloy that is well suited for applications

requiring high strength in temperature ranges from cryogenic up to 1400 degrees

Fahrenheit. Inconel 718 also exhibits excellent tensile and impact strength. Inconel alloys

are oxidation and corrosion resistant materials well suited for service in extreme

environments. When heated, Inconel forms a thick, stable, passivating oxide layer

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protecting the surface from further attack. Inconel retains strength over a wide

temperature range, attractive for high temperature applications where aluminum and steel

would succumb to creep as a result of thermally-induced crystal vacancies (see Arrhenius

equation). Inconel's high temperature strength is developed by solid solution

strengthening or precipitation strengthening, depending on the alloy. In age hardening or

precipitation strengthening varieties, small amounts of niobium combine with nickel to

form the intermetallic compound Ni3Nb or gamma prime (γ'). Gamma prime forms small

cubic crystals that inhibit slip and creep effectively at elevated temperatures.

Element Min Max

Carbon -- 0.08

Manganese -- 0.35

Silicon -- 0.35

Phosphorus -- 0.015

Sulfur -- 0.015

Nickel + Cobalt 50.0 55.0

Chromium 17.0 21.0

Cobalt -- 1.00

Iron Balance

Aluminum 0.35 0.80

Molybdenum 2.80 3.30

Titanium 0.65 1.15

Boron 0.001 0.006

Copper -- 0.15

Cb + Ta 4.75 5.50

Table 2.4 – Composition of Inconel 718

2.8.2 PHYSICAL PROPERTIES:

Inconel 718 is a Nickel-Chromium alloy being precipitation hardenable and

having high creep-rupture strength at high temperatures to about 700°C (1290°F). It has

higher strength than Inconel X-750 and better mechanical properties at lower

temperatures than Nimonic 90 and Inconel X-750.

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PARTICULARS SPECIFICATION

Density 8.19 g/cm3

Melting point 1336 °C

Co-Efficient of Expansion 13.0 µm/m.°C(20-100 °C)

Modulus of rigidity 77.2 kN/mm2

Modulus of elasticity 204.9kN/mm2

Table 2.5 – Physical prorperties

2.8.3 MECHANICAL PROPERTIES:

Alloy 718 is a precipitation hardenable nickel-based alloy designed to display

exceptionally high yield, tensile and creep-rupture properties at temperatures up to

1300°F. The sluggish age-hardening response of alloy 718 permits annealing and welding

without spontaneous hardening during heating and cooling. This alloy has excellent

weldability when compared to the nickel-base super alloys hardened by aluminum and

titanium. This alloy has been used for jet engine and high-speed airframe parts such as

wheels, buckets, spacers, and high temperature bolts and fasteners.

2.8.4 APPLICATIONS:

Inconel is often encountered in extreme environments. It is common in gas turbine

blades, seals, and combustors, as well as turbocharger rotors and seals, electric

submersible well pump motor shafts, high temperature fasteners, chemical processing and

pressure vessels, heat exchanger tubing, steam generators in nuclear pressurized water

reactors, natural gas progressing with contaminants such as H2S and CO2, firearm sound

suppressor blast baffles, and Formula One and NASCAR exhaust systems. Inconel is

increasingly used in the boilers of waste incinerators.North American Aviation

constructed the skin of the X-15 rocket plane out of an Inconel alloy known as "Inconel

X".

2.9 WEAR:

Wear is commonly defined as the undesirable deterioration of a component by the

removal of material from its surface. It occurs by displacement and detachment of

particles from surface. The mechanical properties of steel are sharply reduced due to

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wear. The wear of material may be due to the friction of metals against each other,

eroding effect of liquid and gaseous media, scratching of solid particles from the surface

and other surface phenomena. In laboratory tests, wear are usually determined by weight

loss in a material and wear resistance is characterized by the loss in weight per unit area

per unit time. There are following principle types of wear as described below:

The definition of wear does not include loss of dimension from plastic deformation,

although wear has occurred despite no material removal. This definition also fails to

include impact wear, where there is no sliding motion, cavitation, where the counter body

is a fluid, and corrosion, where the damage is due to chemical rather than mechanical

action. The working life of an engineering component is over when dimensional losses

exceed the specified tolerance limits. Wear, along with other ageing processes such as

fatigue, creep, and fracture toughness, causes progressive degradation of materials with

time, leading to failure of material at an advanced age. Under normal operating

parameters, the property changes during usage normally occur in three different stages as

follows:-

Primary or early stage or run-in period, where rate of change can be high.

Secondary or mid-age process where a steady rate of aging process is

maintained. Most of the useful or working life of the component is

comprised in this stage.

Tertiary or old-age stage, where a high rate of aging leads to rapid failure

2.9.1 ADHESIVE WEAR:

Adhesive wear, material transfer from one surface to another caused by direct

contact and plastic deformation. Adhesive wear occurs when two bodies slides over each

other, or are pressed into one another, which promote material transfer between the two

surfaces. However, material transfer is always present when two surfaces are aligned

against each other for a certain amount of time and the wear-categorization and the cause

for material transfer have been a source for discussion and argumentation amongst

researchers around the world for quite some time and there are frequent

misinterpretations, misunderstandings due to overlaps and symbiotic relations between

mechanisms as previously mentioned. The above description and distinction between

"cohesive" adhesive forces and its counterpart, such as adhesive "wear" are quite common

and usually goes for most researchers in engineering science and physics.

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Having described the restriction on the subject wear, we can focus on what causes

material transfer. Adhesive wear can be described as plastic deformation of very small

fragments within the surface layer when two surfaces slides against each other.

The asperities (i.e., microscopic high points) found on the mating surfaces will penetrate

the opposing surface and develop a plastic zone around the penetrating asperity.

Dependent on the surface roughness and depth of penetration will the asperity cause

damage on the oxide surface layer or even the underlying bulk material. In initial

asperity/asperity contact, fragments of one surface are pulled off and adhere to the other,

due to the strong adhesive forces between atoms. It is thereby clear that physical-chemical

adhesive interaction between the surfaces plays a role in the initial build up process but

the energy absorbed in plastic deformation and movement is the main cause for material

transfer and wear

Fig 2.9 Adhesive wear

2.9.2 ABRASIVE WEAR:

Abrasive wear occurs when a hard rough surface slides across a softer

surface. ASTM (American Society for Testing and Materials) defines it as the loss of

material due to hard particles or hard protuberances that are forced against and move

along a solid surface.

Abrasive wear is commonly classified according to the type of contact and the contact

environment. The type of contact determines the mode of abrasive wear. The two modes

of abrasive wear are known as two-body and three-body abrasive wear. Two-body wear

occurs when the grits, or hard particles, are rigidly mounted or adhere to a surface, when

they remove the material from the surface. The common analogy is that of material being

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removed with sand paper. Three-body wear occurs when the particles are not constrained,

and are free to roll and slide down a surface. The contact environment determines

whether the wear is classified as open or closed. An open contact environment occurs

when the surfaces are sufficiently displaced to be independent of one another

There are a number of factors which influence abrasive wear and hence the manner of

material removal. Several different mechanisms have been proposed to describe the

manner in which the material is removed. Three commonly identified mechanisms of

abrasive wear are:

Plowing

Cutting

Fragmentation

Fig 2.10 Abrasive wear

2.9.3 Erosive wear:

Erosive wear is caused by the impact of particles of solid or liquid against the

surface of an object. The impacting particles gradually remove material from the surface

through repeated deformations and cutting actions. It is a widely encountered mechanism

in industry. A common example is the erosive wear associated with the movement of

slurries through piping and pumping equipment. The rate of erosive wear is dependent

upon a number of factors. The material characteristics of the particles, such as their shape,

hardness, impact velocity and impingement angle are primary factors along with the

properties of the surface being eroded. The impingement angle is one of the most

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important factors and is widely recognized in literature. For ductile materials the

maximum wear rate is found when the impingement angle is approximately 30o, whilst

for non ductile materials the maximum wear rate occurs when the impingement angle is

normal to the surface. They can be classified as

Blast erosion which are caused by solid particles which are carried by a stream of

gases or accelerated by a certain force

Flush erosion, which occurs by flowing action of liquid stream carrying solid

particles

Rain erosion, which is caused by liquid, drops impinging on solid surface

Corrosion Erosion which is caused by imploding cavities in the liquid

Thermal erosion which results in material loss by melting and evaporation due to

action of thermal, mechanical, electrical or magnetic forces

Fig 2.11 Erosive wear

2.9.4 SURFACE FATIGUE:

Surface fatigue is a process by which the surface of a material is weakened by

cyclic loading, which is one type of general material fatigue. It is characterized by crack

formation and flaking of material. The rolling and sliding contact of the solids and liquids

can result in cyclic surface stressing. Fatigue of material proceeds in a sequence of elastic

and plastic deformation, work hardening and work softening, crack initiates and crack

propagates.

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Fig 2.12-Surface fatigue

2.9.5 FRETTING WEAR:

Fretting wear is the repeated cyclical rubbing between two surfaces, which is

known as fretting, over a period of time which will remove material from one or both

surfaces in contact. It occurs typically in a bearing, although most bearings have their

surfaces hardened to resist the problem. Another problem occurs when cracks in either

surface are created, known as fretting fatigue. It is the more serious of the two phenomena

because it can lead to catastrophic failure of the bearing. An associated problem occurs

when the small particles removed by wear are oxidized in air. The oxides are usually

harder than the underlying metal, so wear accelerates as the harder particles abrade the

metal surfaces further.

Fig 2.13- Schematic fretting wear

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2.9.6 CORROSIVE WEAR:

This form of wear arises when a sliding surface is in a corrosive environment and

sliding action continuously remove the protective product thus exposing fresh surface to

further corrosive attack. Factors affecting wear:

Physical properties of the material

Micro structural elements

Types of lubrication

Loading conditions

Surface finish

Temperature

Environmental factors

Sliding distance and speed

Fig 2.14- Schematic corrosive wear

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2.10 Review of International Published Paper: 2.10.1 Title of the paper: “Study of Dry Sliding Wear of Plasma Sprayed

Mo-Ni/Cr - Ti-6Al-4V Tribo Pair” Name of the Author: Prince M, Gopalakrishnan P, Duraiselvam

Muthukannan, More Satish D, Naveen R and Natarajan S

Name of the journal and Year of publication: European Journal of

Scientific Research ISSN 1450-216X Vol.37 No.1 (2009), pp.41-48

Materials selected: Mo-Ni/Cr - Ti-6Al-4V

Type of process adopted: pin-on-disc tribometer

Testing & Results: The wear behavior of Mo-Ni/Cr pin on Ti-6Al-4V disc

tribo pair was analyzed by conducting wear studies underconstant load of 1

Kg, sliding speed of 1.0 m/sec, sliding distance of 1000 m under

roomtemperature(30oC) and high temperature(250

oC) using a pin-on-disc

tribometer.

Conclusion: The mass loss of the plasma sprayed Mo-Ni/Cr and Ti-6Al-4V

reduces with increase in Mo content till 40% Mo-60 Ni/Cr and then increases

with increase in Mo content. The wear rate is directly related to the surface

temperatures, thus showing the importance of thermal softening effects. Thus,

as surface temperature is increased, the plastic strain rate at the contacting

asperities also increased which leads to an increase in wear

2.10.2 Title of paper: “Dry sliding wear characteristicsof 0.13 wt. % carbon steel”

Name of the Author: By V.k. Gupta1, S. Ray, O.P. Pandey

Name of the Journal and Year of Publication: Materials Science-Poland,

Vol. 26, No. 3, 2008

Material Selected: Carbon steel

Type of process adopted: Tribometer( pin-on-disk)

Testing & Results: Wear characteristics of 0.13 wt. % plain carbon steel, heat

treated under various conditions, were monitored on a standard pin-on-disk

wear testing machine under the normal loads of 2.5, 4.5 and 5.5 kg and at a

constant sliding velocity of 1 m/s. Weight loss of the specimen was measured

at various time intervals to obtain wear rate.

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Conclusion: The volume loss in wear increases with sliding distance.

2.10.3 Title of paper: “Dry sliding wear behavior of Al 2219/SiC metal matrix

composites”

Name of the Author: By S. Basavarajappa, G. Handramohan,

R.Subramanian, A. Chandrasekar

Name of the Journal and Year of Publication: Materials Science-Poland,

Vol. 24, No. 2/1, 2006

Material Selected: Al 2219/SiC

Type of process adopted: Tribometer( pin-on-disk)

Testing & Results: The present study deals with investigations relating to dry

sliding wear behaviour of the Al 2219 alloy,reinforced with SiC particles in 0–

15 wt. % in three steps. Unlubricated pin-on disc tests were conducted to

examine the wear behaviour of the aluminium alloy and its composites. The

tests were conducted at varying loads, from 0 to 60 N and a sliding speeds of

1.53 m/s, 3 m/s, 4.6 m/s, and 6.1 m/s for a constant sliding distance of 5000 m.

Conclusion: The wear rate of both reinforced and unreinforced specimens

increases as the load increases. The unreinforced alloy specimen seized much

earlier than the composites.A combination of adhesion and delamination wear

was in operation.

2.10.4 Title of paper: “Friction and wear characteristic of ductile iron in dry sliding

conditions.”

Name of the Author: By P.R. Gangasani

Name of the Journal and Year of Publication: 2003 Keith Millis

symposium on ductile cast iron

Material Selected: ductile cast iron.

Type of process adopted: Multi-specimen wear testing machine.

Testing & Results: There could be number of situation where ductile iron

parts must be rubbing against hardened steel parts under dry conditions for a

part of time or full time. Using, laboratory method the wear and frictions

characteristics of the metal is determined.

Conclusion: when interfacial pressure is relatively lower ,than the wear loss

depends on starting hardness.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 31

2.10.5 Title of paper: “Tribochemistry in sliding wear of TiCN–Ni-based cermets”

Name of the Author: By B.V. Manoj Kumar and Bikramjit Basu

Name of the Journal and Year of Publication: J. Mater. Res., Vol. 23,

No. 5, May 2008

Material Selected: TiCN–Ni-based cermets

Type of process adopted: reciprocating pin-on-flat tribometer

Testing & Results: The tailoring of cermet composition to improve

tribological properties requires carefulchoice of the type of secondary

carbide. To investigate this aspect, a number of slidingtests were carried

out on baseline TiCN–20Ni cermet and TiCN–20wt%Ni–10 wt% XC

cermets at varying loads of 5N, 20N, and 50N against bearing. With these

experiments, we attempted to answer some of the pertinent issues: (i) how

does the type of secondary carbide (WC/NbC/TaC/HfC) influence friction

and wear behavior, and is such influence dependent on load?; and (ii) how

does the secondary carbide addition affect the stability and composition of

the tribochemical layer under the selected sliding conditions?

Conclusion: One of the important observations in this study is that the

friction and wear properties do not exhibit any correlation with mechanical

properties (i.e., hardness and KIc) when tribochemcial layer formation is

dominant (at a load of 20N or 50N) at the interface of the investigated

tribocontacts. However, an inverse relation of W_ with the hardness is

observed when the abrasion or adhesion of debris is dominant at low load

(5N).

.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 32

CHAPTER 3

EXPERIMENTAL

DETAILS

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 33

CHAPTER 3

EXPERIMENTAL DETAILS

3.1 STAGES INVOLVED:

Base metal: Mild Steel

Coating material: Inconel 718 alloy.

Stage 1:

Prepare the raw sample by cutting, rough turning and by filing operations.

Stage 2:

Specimens are prepared and cut to the following size:

10mm diameter and 20 mm length

Stage 3:

The coating material (Inconel 718) was plasma sprayed on to the base metal to a

thickness of 200µm on side 1 and to a thickness of 250 µm on side 2.

Stage 4:

Pin on Disc wear test are conducted by varying load from 10 to 50 Newton and

constant speed conditions at 300 and 500 rpm and constant track radius of 30mm.

Stage 5:

Each test is conducted with all possible accuracy taking each specimen at a time

for 30 minutes.

Stage 6:

Data of the wear, frictional resistance and the temperature is noted down every

minute and accordingly graphs are plotted.

3.2 SURFACE PREPARATION BEFORE COATING:

The specimen is cleaned to remove all dust particles. It is then grit blasted before

plasma spraying to create enough surface roughness to ensure a strong mechanical bond

between coating and substrate. Then a layer of bonding agent is applied to the base metal

to provide good bonding for the coating material on base metal.

3.3 PLASMA SPRAYING TECHNIQUE:

Inconel 718 powder is heated to about 10000k so that it is melted and ionized to

plasma state. Then it is sprayed using a gun along with hydrogen and argon gas onto the

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 34

base metal from a distance of about 15cm for duration of 5 min. The voltage maintained

is about 150V.

PARTICULARS SPECIFICATION

Voltage 150 V

Current 495amps

Inert Gases

Primary gas: hydrogen (flow rate-100m3/min)

Secondary gas: argon ( flow rate -100m3/min)

Inconel 718 powder 100gm/min

Specimen Preparation:

Cleaning with Trichloroethylene

24 mesh Al2O3 grit blasting

Coating:

Bond coating - Ni, Cr

Coating thickness – Inconel 718 (200-250icrons)

Distance of spray gun from specimen 6 inches/15cm

Table 3.1 Specification of plasma spray coatings

Fig3.1: Side view of spray gun Fig3.2: Front view of spray gun

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 35

Fig3.3: Mixing chamber Fig3.4: Plasma spray controls

3.4 SPECIMENS FOR TESTING:

Specimens used in this project are illustrated below:

Fig3.5: Uncoated sample (mild steel of 10mm diameter x 20mm height)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 36

Fig3.6: Coated sample (mild steel coated with Inconel 718 of 10mm diameter x

20mm height)

3.5 MEASUREMENT OF WEAR RATE USING PIN-ON-

DISC WEAR TESTING MACHINE (TRIBOMETER):

A pin-on-disc machine or a tribometer consists of a stationary "pin" under an

applied load in contact with a rotating disc. The pin can have any shape to simulate a

specific contact, but flat tips are often used to simplify the contact geometry. Friction is

determined by the ratio of the frictional force to the loading force on the pin.

Fig 3.7 Principle behind a Tribometer/ Pin-on-disc wear testing machine

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 37

Wear test of Mild Steel specimens coated with Inconel 718. Sample of diameter

10mm and height 20mm, were studied using standard pin on disc wear test rig.

PARTICULARS SPECIFICATION

Pin size 3 to 12mm

Disc size Dia.120mmx8mm thick

Wear tack radius 20mm to 60mm

Sliding speed range 26m/s to 6m/s

Disc rotating speed 100 to 2000rpm

Normal load maximum200N

Frictiona force 0-200N digital readout

Wear measurement range 4mm digital readout

Input Power 230V, 5A, Iphase, 50Hz

Table 3.2 Specification of a Tribometer / Pin-on-disc wear testing machine

Fig 3.8 Tribometer/Pin-on-disc wear testing machine

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 38

3.5.1 APPARATUS USED: Pin on disc wear testing machine with digital indicator and digital weighing

machine.

Fig 3.9 Pin-On-Disc machine’s Fig.3.10 Digital weighing machine

Digital display

3.5.2MATERIALS USED: Acetone LR( cleansing solution), Cotton, Emery paper, etc.

3.5.3 PROCEDURE: Clean the surface of the disc and specimen by acetone LR.

Switch ON the motor.

Polish the surface using emery paper by pressing hard against the circular disc.

Again clean the surface using cleansing solution.

Switch OFF the motor.

Fix the specimen (Pin) on the horizontal arm and tighten the specimen by help of

Allen screws and set the track radius using the scale provided.

Set the time to zero and preset it for 30minutes count.

Switch ON the motor and fix the speed of disc (rpm) by digital tachometer.

Adjust the displacement sensor to read zero.

For every minute note down the following readings.

a) Wear in microns. b) Frictional Force. c) Temperature.

Repeat the above procedure on the other specimen for a given period at constant

sliding velocity and increasing load.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 39

CHAPTER 4

RESULTS & DISCUSSION

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 40

CHAPTER 4

RESULTS & DISCUSSION

4.1 EVALUATING OF WEAR RATE USING PIN ON DISC

WEAR TESTER:

TABULATION:

For Coated and Uncoated Specimens

(For constant speed, track radius and varying load)

Track radius : 30mm

Speed : 300 rpm and 500rpm

Load : 10-50N (steps of 10N)

Formula used:

COF = Frictional force/ Normal force (where COF- Co-efficient of

friction)………………………………………………………………...………(4.1)

Sliding velocity(v)= (where D-track diameter in mm, N-speed in

rpm)………………………………………………………………...…………..(4.2)

Sliding distance (L)= sliding velocity x time= v x T m (T-time in Seconds)...(4.3)

Wear rate = ………………………………………..(4.4)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 41

SPECIMEN : A1

LOAD : 10 N

INTIALWT IN gms : 11.545

FINAL WT IN gms : 11.535

WEIGHT LOSS : 0.01

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

9

15

19

20

21

22

22

23

25

27

27

28

28

29

29

30

31

31

31

31

31

32

32

32

32

33

33

33

33

33

Frict

on

force(

N)

0.1

1.5

1.6

1.6

1.7

1.8

1.8

1.8

1.9

2

2

2

2.3

2.3

2.4

2.5

2.6

2.6

2.7

2.8

2.8

2.9

2.9

3

3

3.1

3.1

3.2

3.2

3.4

Temp

eratu

re

30

31

31

32

32

31

33

32

32

32

32

32

32

32

33

35

36

36

36

36

36

36

36

37

37

37

37

37

37

37

Coeffi

cient

of

frictio

n

(COF

)

0.0

1

0.1

5

0.1

6

0.1

6

0.1

7

0.1

8

0.1

8

0.1

8

0.1

9

0.2

0.2

0.2

0.2

3

0.2

3

0.2

4

0.2

5

0.2

6

0.2

6

0.2

7

0.2

8

0.2

8

0.2

9

0.2

9

0.3

0.3

0.3

1

0.3

1

0.3

2

0.3

2

0.3

4

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 0.0

01274

0.0

01062

0.0

00897

0.0

00708

0.0

00595

0.0

00519

0.0

00445

0.0

00407

0.0

00393

0.0

00382

0.0

00348

0.0

0033

0.0

00305

0.0

00293

0.0

00274

0.0

00265

0.0

00258

0.0

00244

0.0

00231

0.0

00219

0.0

00209

0.0

00206

0.0

00197

0.0

00189

0.0

00181

0.0

0018

0.0

00173

0.0

00167

0.0

00161

0.0

00156

Table 4.1(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 10N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 42

SPECIMEN : A2

LOAD : 20 N

INTIALWT IN gms : 12.115

FINAL WT IN gms : 12.106

WEIGHT LOSS : 0.009

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm) 24

24

24

26

26

26

27

28

30

30

31

31

31

31

32

34

33

33

33

36

36

40

41

41

41

41

41

42

42

43

Frict

on

force(

N)

4.7

5.3

5.3

5.4

5.5

5.8

8.5

8.5

9

9.2

9.7

9.8

9.8

9.8

9.9

10

10.1

10.1

10.2

10.2

10.3

10.3

10.4

10.5

10.6

10.6

10.6

10.8

10.8

10.9

Temp

eratu

re

31

34

34

34

35

34

34

35

36

39

39

35

35

35

35

36

39

38

37

38

36

38

39

38

37

33

39

36

35

37

Coeffi

cient

of

frictio

n

(COF

)

0.2

35

0.2

65

0.2

65

0.2

7

0.2

75

0.2

9

0.4

25

0.4

25

0.4

5

0.4

6

0.4

85

0.4

9

0.4

9

0.4

9

0.4

95

0.5

0.5

05

0.5

05

0.5

1

0.5

1

0.5

15

0.5

15

0.5

2

0.5

25

0.5

3

0.5

3

0.5

3

0.5

4

0.5

4

0.5

45

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 0.0

01667

0.0

00833

0.0

00556

0.0

00451

0.0

00361

0.0

00301

0.0

00268

0.0

00243

0.0

00231

0.0

00208

0.0

00196

0.0

00179

0.0

00166

0.0

00154

0.0

00148

0.0

00148

0.0

00135

0.0

00127

0.0

00121

0.0

00125

0.0

00119

0.0

00126

0.0

00124

0.0

00119

0.0

00114

0.0

0011

0.0

00105

0.0

00104

0.0

00101

9.9

5E

-05

Table 4.2(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 20N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 43

SPECIMEN : A3

LOAD : 30 N

INTIALWT IN gms : 11.265

FINAL WT IN gms : 11.254

WEIGHT LOSS : 0.009

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm) 24

25

25

25

25

26

27

28

30

30

31

31

32

33

34

34

35

35

35

36

37

40

42

44

44

46

47

48

50

52

Frict

on

force(

N)

10.8

13.2

15.4

15.4

15.5

15.6

15.6

15.6

15.7

15.8

15.9

15.9

15.9

15.9

16

16.1

16.2

16.2

16.3

16.3

16.4

16.4

16.4

16.5

16.6

16.6

16.7

16.8

16.8

16.9

Temp

eratu

re

39

46

47

43

43

38

38

38

39

40

39

39

38

39

39

40

39

38

38

37

37

38

38

38

39

39

38

38

38

38

Coeffi

cient

of

frictio

n

(COF

)

0.3

6

0.4

4

0.5

13333

0.5

13333

0.5

16667

0.5

2

0.5

2

0.5

2

0.5

23333

0.5

26667

0.5

3

0.5

3

0.5

3

0.5

3

0.5

33333

0.5

36667

0.5

4

0.5

4

0.5

43333

0.5

43333

0.5

46667

0.5

46667

0.5

46667

0.5

5

0.5

53333

0.5

53333

0.5

56667

0.5

6

0.5

6

0.5

63333

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 4.6

3E

-05

2.3

1E

-05

1.5

4E

-05

1.1

6E

-05

3.7

E-0

5

3.0

9E

-05

3.3

1E

-05

3.4

7E

-05

3.0

9E

-05

2.7

8E

-05

3.7

9E

-05

3.8

6E

-05

3.9

2E

-05

3.6

4E

-05

3.7

E-0

5

3.7

6E

-05

3.5

4E

-05

3.3

4E

-05

3.6

5E

-05

3.9

4E

-05

3.9

7E

-05

4E

-05

3.8

2E

-05

4.0

5E

-05

4.0

7E

-05

4.1

E-0

5

3.9

4E

-05

3.8

E-0

5

3.8

3E

-05

3.7

E-0

5

Table 4.3(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 30N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 44

SPECIMEN : A4

LOAD : 40 N

INTIALWT IN gms : 11.845

FINAL WT IN gms : 11.835

WEIGHT LOSS : 0.01

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

8

21

21

22

25

26

37

52

53

55

57

57

58

58

59

59

59

61

61

63

63

63

63

67

67

67

68

68

67

69

Frict

on

force(

N)

7.6

8.2

8.8

8.8

8.8

9

9.8

10

10

10

10.1

10.1

10.2

10.4

10.5

10.6

10.6

10.7

10.7

10.7

10.8

10.8

10.9

10.9

11

11.1

11.2

11.5

11.9

11.9

Temp

eratu

re

30

30

31

31

32

33

33

34

34

35

35

34

36

35

36

37

38

38

36

38

38

37

38

39

39

37

38

37

38

39

Coeffi

cient

of

frictio

n

(COF

)

0.1

9

0.2

05

0.2

2

0.2

2

0.2

2

0.2

25

0.2

45

0.2

5

0.2

5

0.2

5

0.2

525

0.2

525

0.2

55

0.2

6

0.2

625

0.2

65

0.2

65

0.2

675

0.2

675

0.2

675

0.2

7

0.2

7

0.2

725

0.2

725

0.2

75

0.2

775

0.2

8

0.2

875

0.2

975

0.2

975

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 0.0

00278

0.0

00365

0.0

00243

0.0

00191

0.0

00174

0.0

0015

0.0

00184

0.0

00226

0.0

00204

0.0

00191

0.0

0018

0.0

00165

0.0

00155

0.0

00144

0.0

00137

0.0

00128

0.0

00121

0.0

00118

0.0

00111

0.0

00109

0.0

00104

9.9

4E

-05

9.5

1E

-05

9.6

9E

-05

9.3

1E

-05

8.9

5E

-05

8.7

4E

-05

8.4

3E

-05

8.0

2E

-05

7.9

9E

-05

Table 4.4(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 40N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 45

SPECIMEN : A5

LOAD : 50 N

INTIALWT IN gms : 12.203

FINAL WT IN gms : 11.196

WEIGHT LOSS : 0.009

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

4

16

19

20

20

21

21

22

23

24

25

26

27

27

28

28

28

28

30

31

32

33

33

34

34

35

36

36

37

38

Frict

on

force(

N)

6.2

7.2

8.6

8.7

9

9.7

10.2

10.2

10.2

10.3

10.7

10.9

11

11.3

11.3

11.4

11.4

11.4

11.7

11.8

11.8

11.8

11.8

11.9

11.9

12

12

12

12.1

12.2

Temp

eratu

re

30

30

30

31

31

32

33

33

33

34

34

34

34

36

35

35

35

36

36

36

36

38

38

38

39

39

39

39

38

39

Coeffi

cient

of

frictio

n

(COF

)

0.2

0591

0.3

0989

0.2

2834

0.5

9327

0.6

1366

0.7

1764

0.6

157

0.5

9735

0.5

1376

0.6

1366

0.5

5454

0.6

1162

0.5

8104

0.6

0143

0.5

3211

0.5

5454

0.5

4434

0.5

1784

0.6

0958

0.6

3201

0.5

3007

0.5

7696

0.5

7288

0.6

9725

0.6

9113

0.5

5657

0.5

8919

0.5

1988

0.5

5454

0.5

525

Slidin

g

distan

ce (m)

94.2

477

188.4

95

282.7

43

376.9

91

471.2

39

565.4

86

659.7

34

753.9

82

848.2

29

942.4

77

1036.7

2

1130.9

7

1225.2

2

1319.4

7

1413.7

2

1507.9

6

1602.2

1

1696.4

6

1790.7

1

1884.9

5

1979.2

2073.4

5

2167.7

2261.9

4

2356.1

9

2450.4

4

2544.6

9

2638.9

4

2733.1

8

2827.4

3

Wear

rate

(mm3/

Nm)

1.7

E-0

5

6.8

E-0

5

7.9

E-0

5

1.7

E-0

5

4.1

E-0

5

1.1

E-0

5

9.7

E-0

6

6.4

E-0

6

9.4

E-0

6

1E

-05

7.7

E-0

6

7.1

E-0

6

6.5

E-0

6

3.6

E-0

6

4.5

E-0

6

5.3

E-0

6

6E

-06

7.6

E-0

6

8E

-06

8.5

E-0

6

8.9

E-0

6

6.2

E-0

6

8.9

E-0

6

7.1

E-0

6

6.1

E-0

6

6.5

E-0

6

6.9

E-0

6

1E

-05

8.8

E-0

6

9.1

E-0

6

Table 4.5(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 50N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 46

SPECIMEN : A6

LOAD : 10 N

INTIALWT IN gms : 11.173

FINAL WT IN gms : 11.165

WEIGHT LOSS : 0.008

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

2

3

4

5

8

13

14

14

17

17

18

20

22

22

22

24

25

26

25

27

27

28

29

30

32

33

33

34

34

35

Frict

on

force(

N)

0.5

1

1.5

1.8

2.4

2.4

2.9

3.2

3.3

3.3

3.4

3.4

3.9

4.1

4.2

4.2

4.3

4.5

4.6

4.7

4.7

4.7

4.7

4.7

4.8

4.8

4.9

5

5.1

5.1

Temp

eratu

re

28

30

30

29

31

32

33

33

34

34

34

35

35

35

35

35

34

34

35

34

33

35

34

33

34

33

35

35

34

35

Coeffi

cient

of

frictio

n

(COF

)

0.0

5

0.1

0.1

5

0.1

8

0.2

4

0.2

4

0.2

9

0.3

2

0.3

3

0.3

3

0.3

4

0.3

4

0.3

9

0.4

1

0.4

2

0.4

2

0.4

3

0.4

5

0.4

6

0.4

7

0.4

7

0.4

7

0.4

7

0.4

7

0.4

8

0.4

8

0.4

9

0.5

0.5

1

0.5

1

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 0.0

00167

0.0

00125

0.0

00111

0.0

00104

0.0

00133

0.0

00181

0.0

00167

0.0

00146

0.0

00157

0.0

00142

0.0

00136

0.0

00139

0.0

00141

0.0

00131

0.0

00122

0.0

00125

0.0

00123

0.0

0012

0.0

0011

0.0

00113

0.0

00107

0.0

00106

0.0

00105

0.0

00104

0.0

00107

0.0

00106

0.0

00102

0.0

00101

9.7

7E

-05

9.7

2E

-05

Table 4.6(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 10N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 47

SPECIMEN : A7

LOAD : 20 N

INTIALWT IN gms : 12.422

FINAL WT IN gms : 12.413

WEIGHT LOSS : 0.009

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

2

16

18

25

26

26

26

27

30

31

31

31

33

35

37

36

36

40

41

42

42

43

44

45

45

47

47

49

49

50

Frict

on

force(

N)

8.6

13.2

13.3

13.3

13.3

13.5

13.6

13.7

13.8

14.3

14.5

14.5

14.6

14.7

14.8

14.8

14.8

14.9

14.9

15

15.1

15.1

15.1

15.2

15.2

15.3

15.3

15.4

15.5

15.5

Temp

eratu

re

30

31

31

32

33

34

34

35

35

36

36

36

37

37

37

38

38

38

39

39

39

39

39

39

38

39

38

38

38

39

Coeffi

cient

of

frictio

n

(COF

)

0.4

3

0.6

6

0.6

65

0.6

65

0.6

65

0.6

75

0.6

8

0.6

85

0.6

9

0.7

15

0.7

25

0.7

25

0.7

3

0.7

35

0.7

4

0.7

4

0.7

4

0.7

45

0.7

45

0.7

5

0.7

55

0.7

55

0.7

55

0.7

6

0.7

6

0.7

65

0.7

65

0.7

7

0.7

75

0.7

75

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 8.3

3E

-05

0.0

00333

0.0

0025

0.0

0026

0.0

00217

0.0

00181

0.0

00155

0.0

00141

0.0

00139

0.0

00129

0.0

00117

0.0

00108

0.0

00106

0.0

00104

0.0

00103

9.3

8E

-05

8.8

2E

-05

9.2

6E

-05

8.9

9E

-05

8.7

5E

-05

8.3

3E

-05

8.1

4E

-05

7.9

7E

-05

7.8

1E

-05

0.0

00075

7.5

3E

-05

7.2

5E

-05

7.2

9E

-05

7.0

4E

-05

6.9

4E

-05

Table 4.7(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 20N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 48

SPECIMEN : A8

LOAD : 30 N

INTIALWT IN gms : 12.146

FINAL WT IN gms : 12.130

WEIGHT LOSS : 0.016

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

3

4

10

17

22

26

32

33

34

35

37

38

39

39

40

41

42

42

44

45

45

45

46

47

48

48

48

49

51

Frict

on

force(

N)

2.1

3.2

3.4

3.5

3.5

3.6

3.7

3.7

3.9

3.9

3.9

4

4.5

4.5

4.6

5.8

5.8

5.9

6

6

6

6.2

6.2

6.3

6.4

6.5

6.6

6.7

6.8

8

Temp

eratu

re

29

30

30

31

33

33

33

34

36

36

36

36

37

37

37

37

37

38

38

38

38

39

39

39

39

40

40

40

40

40

Coeffi

cient

of

frictio

n

(COF

)

0.0

7

0.1

06667

0.1

13333

0.1

16667

0.1

16667

0.1

2

0.1

23333

0.1

23333

0.1

3

0.1

3

0.1

3

0.1

33333

0.1

5

0.1

5

0.1

53333

0.1

93333

0.1

93333

0.1

96667

0.2

0.2

0.2

0.2

06667

0.2

06667

0.2

1

0.2

13333

0.2

16667

0.2

2

0.2

23333

0.2

26667

0.2

66667

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 2.7

8E

-05

4.1

7E

-05

3.7

E-0

5

6.9

4E

-05

9.4

4E

-05

0.0

00102

0.0

00103

0.0

00111

0.0

00102

9.4

4E

-05

8.8

4E

-05

8.5

6E

-05

8.1

2E

-05

7.7

4E

-05

7.2

2E

-05

6.9

4E

-05

6.7

E-0

5

6.4

8E

-05

6.1

4E

-05

6.1

1E

-05

5.9

5E

-05

5.6

8E

-05

5.4

3E

-05

5.3

2E

-05

5.2

2E

-05

5.1

3E

-05

4.9

4E

-05

4.7

6E

-05

4.6

9E

-05

4.7

2E

-05

Table 4.8(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 30N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 49

SPECIMEN : A9

LOAD : 40 N

INTIALWT IN gms : 12.006

FINAL WT IN gms : 11.993

WEIGHT LOSS : 0.013

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

8

11

18

19

20

26

26

26

27

27

29

29

30

32

34

34

35

35

35

36

37

37

38

43

43

43

44

44

45

46

Frict

on

force(

N)

2.8

2.9

2.9

3.4

3.7

3.7

3.8

3.9

4

4

4

4

4.1

4.2

4.3

4.4

4.6

4.7

4.7

4.8

5.1

5.4

5

5.1

5.2

5.2

5.3

5.3

5.5

5.8

Temp

eratu

re

30

31

31

32

34

33

33

34

33

34

35

34

34

35

36

35

36

35

36

36

36

35

36

36

36

36

37

37

37

37

Coeffi

cient

of

frictio

n

(COF

)

0.0

7

0.0

725

0.0

725

0.0

85

0.0

925

0.0

925

0.0

95

0.0

975

0.1

0.1

0.1

0.1

0.1

025

0.1

05

0.1

075

0.1

1

0.1

15

0.1

175

0.1

175

0.1

2

0.1

275

0.1

35

0.1

25

0.1

275

0.1

3

0.1

3

0.1

325

0.1

325

0.1

375

0.1

45

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 0.0

00167

0.0

00115

0.0

00125

9.9

E-0

5

8.3

3E

-05

9.0

3E

-05

7.7

4E

-05

6.7

7E

-05

6.2

5E

-05

5.6

3E

-05

5.4

9E

-05

5.0

3E

-05

4.8

1E

-05

4.7

6E

-05

4.7

2E

-05

4.4

3E

-05

4.2

9E

-05

4.0

5E

-05

3.8

4E

-05

3.7

5E

-05

3.6

7E

-05

3.5

E-0

5

3.4

4E

-05

3.7

3E

-05

3.5

8E

-05

3.4

5E

-05

3.4

E-0

5

3.2

7E

-05

3.2

3E

-05

3.1

9E

-05

Table 4.9(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 40N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 50

SPECIMEN : A10

LOAD : 50 N

INTIALWT IN gms : 11.754

FINAL WT IN gms : 11.735

WEIGHT LOSS : 0.019

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm) 24

39

39

43

49

50

54

57

61

67

69

76

76

76

76

78

79

81

80

82

83

84

85

86

86

86

86

87

88

89

Frict

on

force(

N)

18.4

18.9

18.9

19

22.1

22.8

22.8

22.9

23

23.1

23.5

23.5

23.7

23.8

23.8

24

24.2

24.4

24.4

24.4

24.4

24.5

24.5

24.7

24.7

24.7

24.7

24.9

24.9

25.3

Temp

eratu

re

30

32

33

33

33

34

34

34

34

35

35

35

36

36

36

36

37

37

37

37

38

38

38

38

39

39

39

39

40

40

Coeffi

cient

of

frictio

n

(COF

)

0.3

68

0.3

78

0.3

78

0.3

8

0.4

42

0.4

56

0.4

56

0.4

58

0.4

6

0.4

62

0.4

7

0.4

7

0.4

74

0.4

76

0.4

76

0.4

8

0.4

84

0.4

88

0.4

88

0.4

88

0.4

88

0.4

9

0.4

9

0.4

94

0.4

94

0.4

94

0.4

94

0.4

98

0.4

98

0.5

06

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm)

0.0

004

0.0

00325

0.0

00217

0.0

00179

0.0

00163

0.0

00139

0.0

00129

0.0

00119

0.0

00113

0.0

00112

0.0

00105

0.0

00106

9.7

4E

-05

9.0

5E

-05

8.4

4E

-05

8.1

3E

-05

7.7

5E

-05

0.0

00075

7.0

2E

-05

6.8

3E

-05

6.5

9E

-05

6.3

6E

-05

6.1

6E

-05

5.9

7E

-05

5.7

3E

-05

5.5

1E

-05

5.3

1E

-05

5.1

8E

-05

5.0

6E

-05

4.9

4E

-05

Table 4.10(UNCOATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 50N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 51

SPECIMEN : B1

LOAD : 10 N

INTIALWT IN gms : 12.739

FINAL WT IN gms : 12.737

WEIGHT LOSS : 0.002

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

1

1

1

1

1

3

2

1

2

1

2

3

1

1

1

1

1

1

1

3

1

3

2

2

2

1

1

1

1

Frict

on

force(

N)

0.5

1.1

0.8

1.2

3

4.2

5

6.6

7

6.8

6.8

6.9

5

5.8

6.5

7.3

6.5

7

7

6.7

7.4

7.6

6.8

7.1

6.8

7.8

7.9

8

7.9

7.7

Temp

eratu

re

28

28

28

28

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

29

Coeffi

cient

of

frictio

n

(COF

)

0.0

4

0.0

9

0.0

7

0.1

0.2

5

0.3

5

0.4

2

0.5

5

0.5

8

0.5

7

0.5

7

0.5

8

0.4

2

0.4

8

0.5

4

0.6

1

0.5

4

0.5

8

0.5

8

0.5

6

0.6

2

0.6

3

0.5

7

0.5

9

0.5

7

0.6

5

0.6

6

0.6

7

0.6

6

0.6

4

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 0.0

00139

6.9

4E

-05

4.6

3E

-05

3.4

7E

-05

0

2.3

1E

-05

5.9

5E

-05

3.4

7E

-05

1.5

4E

-05

2.7

8E

-05

1.2

6E

-05

2.3

1E

-05

3.2

1E

-05

9.9

2E

-06

9.2

6E

-06

8.6

8E

-06

8.1

7E

-06

7.7

2E

-06

7.3

1E

-06

6.9

4E

-06

1.9

8E

-05

6.3

1E

-06

1.8

1E

-05

1.1

6E

-05

1.1

1E

-05

1.0

7E

-05

5.1

4E

-06

4.9

6E

-06

4.7

9E

-06

4.6

3E

-06

Table 4.11(COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 10N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 52

SPECIMEN : B2

LOAD : 20 N

INTIALWT IN gms : 12.884

FINAL WT IN gms : 12.881

WEIGHT LOSS : 0.003

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

2

3

3

3

2

2

3

2

4

3

4

7

4

3

4

4

4

2

3

2

3

3

4

3

3

3

3

3

3

Frict

on

force(

N)

3.3

4.9

7.4

8.8

11.2

12.2

12.6

13.2

11.8

10.4

10.8

11.9

12.2

13.5

13

13

12.1

11.7

11.6

10.8

10.6

11.7

11.3

12

11.4

11.4

14.1

12.2

12.6

12.3

Temp

eratu

re

25

26

27

27

28

29

29

29

30

30

30

31

31

31

31

32

32

32

32

32

32

32

32

33

33

33

33

33

33

33

Coeffi

cient

of

frictio

n

(COF

)

0.1

55

0.2

35

0.3

6

0.4

3

0.5

5

0.6

0.6

2

0.6

5

0.5

8

0.5

1

0.5

3

0.5

85

0.6

0.6

65

0.6

4

0.6

4

0.5

95

0.5

75

0.5

7

0.5

3

0.5

2

0.5

75

0.5

55

0.5

9

0.5

6

0.5

6

0.6

95

0.6

0.6

2

0.6

05

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 6.9

4E

-05

6.9

4E

-05

6.9

4E

-05

5.2

1E

-05

4.1

7E

-05

2.3

1E

-05

1.9

8E

-05

2.6

E-0

5

1.5

4E

-05

2.7

8E

-05

1.8

9E

-05

2.3

1E

-05

3.2

1E

-05

1.9

8E

-05

1.3

9E

-05

1.7

4E

-05

1.6

3E

-05

1.5

4E

-05

7.3

1E

-06

1.0

4E

-05

6.6

1E

-06

9.4

7E

-06

9.0

6E

-06

1.1

6E

-05

8.3

3E

-06

8.0

1E

-06

7.7

2E

-06

7.4

4E

-06

7.1

8E

-06

6.9

4E

-06

Table 4.12(COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 20N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 53

SPECIMEN : B3

LOAD : 30 N

INTIALWT IN gms : 12.756

FINAL WT IN gms : 12.754

WEIGHT LOSS : 0.002

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

1

1

2

1

3

7

7

7

9

8

10

8

10

9

9

7

10

9

8

7

10

8

12

8

10

10

10

10

12

Frict

on

force(

N)

4.9

5.6

8.4

10

15.4

19.5

18.8

18.8

19.1

15.3

19.1

18.7

17.5

18.9

17.2

17.1

18.9

16.4

17.2

17.1

16.2

13.6

13.1

13.6

13.3

16.3

16.6

15.6

15.1

19.3

Temp

eratu

re

22

22

23

23

23

24

24

24

25

25

25

26

26

26

27

27

27

28

28

28

28

29

29

29

30

30

31

31

32

32

Coeffi

cient

of

frictio

n

(COF

)

0.1

56667

0.1

8

0.2

73333

0.3

26667

0.5

06667

0.6

43333

0.6

2

0.6

2

0.6

3

0.5

03333

0.6

3

0.6

16667

0.5

76667

0.6

23333

0.5

66667

0.5

63333

0.6

23333

0.5

4

0.5

66667

0.5

63333

0.5

33333

0.4

46667

0.4

3

0.4

46667

0.4

36667

0.5

36667

0.5

46667

0.5

13333

0.4

96667

0.6

36667

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 4.6

3E

-05

2.3

1E

-05

1.5

4E

-05

2.3

1E

-05

9.2

6E

-06

2.3

1E

-05

3.9

7E

-05

3.4

7E

-05

3.0

9E

-05

3.7

E-0

5

2.9

5E

-05

3.4

7E

-05

2.4

9E

-05

2.9

8E

-05

2.4

7E

-05

2.3

1E

-05

1.6

3E

-05

2.3

1E

-05

1.9

5E

-05

1.6

2E

-05

1.3

2E

-05

1.8

9E

-05

1.4

1E

-05

1.9

3E

-05

1.3

E-0

5

1.6

E-0

5

1.5

4E

-05

1.4

9E

-05

1.4

4E

-05

1.5

4E

-05

Table 4.13(COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 30N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 54

SPECIMEN : B4

LOAD : 40 N

INTIALWT IN gms : 12.878

FINAL WT IN gms : 12.876

WEIGHT LOSS : 0.002

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

1

2

3

4

6

10

9

14

15

15

18

15

14

16

16

19

19

14

16

18

19

18

18

19

21

22

21

22

24

Frict

on

force(

N)

4.2

7.7

10.4

16

20

22.6

25

27.6

28.1

20.5

19.6

27.5

28.6

23.3

25

22.9

27.5

28.2

30.2

28.2

31.4

32.3

30.4

31.4

30.6

29.4

30.3

31.4

31.4

30.2

Temp

eratu

re

24

24

24

25

25

25

26

26

26

27

27

27

28

28

28

28

29

29

29

29

30

30

31

32

33

33

33

33

33

33

Coeffi

cient

of

frictio

n

(COF

)

0.1

0.1

875

0.2

55

0.3

95

0.4

95

0.5

6

0.6

2

0.6

85

0.6

975

0.5

075

0.4

85

0.6

825

0.7

1

0.5

775

0.6

2

0.5

675

0.6

825

0.7

0.7

5

0.7

0.7

8

0.8

025

0.7

55

0.7

8

0.7

6

0.7

3

0.7

525

0.7

8

0.7

8

0.7

5

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 3.4

7E

-05

1.7

4E

-05

2.3

1E

-05

2.6

E-0

5

2.7

8E

-05

2.8

9E

-05

4.4

6E

-05

3.4

7E

-05

4.6

3E

-05

4.5

1E

-05

4.1

E-0

5

4.3

4E

-05

3.4

7E

-05

2.9

8E

-05

3.2

4E

-05

3.0

4E

-05

3.2

7E

-05

3.0

9E

-05

2.1

9E

-05

2.4

3E

-05

2.4

8E

-05

2.5

3E

-05

2.2

6E

-05

2.1

7E

-05

2.2

2E

-05

2.4

E-0

5

2.4

4E

-05

2.2

3E

-05

2.2

7E

-05

2.3

1E

-05

Table 4.14(COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 40N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 55

SPECIMEN : B5

LOAD : 50 N

INTIALWT IN gms : 12.915

FINAL WT IN gms : 12.913

WEIGHT LOSS : 0.002

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

2

6

4

4

3

3

2

4

2

2

3

3

2

4

2

1

2

6

6

9

4

6

6

6

2

4

6

3

3

2

Frict

on

force(

N)

6.9

5.7

6.9

7.4

5.4

9

10.4

10.3

10.2

7.4

8

7.9

8.5

6.7

7.5

9.3

7.5

8.5

8

8.9

9.8

10.8

9.9

9.7

9.6

10.5

10.5

13.5

12.7

11.7

Temp

eratu

re

28

28

28

29

29

29

29

30

30

30

30

30

30

30

30

30

30

30

30

30

31

31

31

31

31

32

32

32

32

32

Coeffi

cient

of

frictio

n

(COF

)

0.1

34

0.1

1

0.1

34

0.1

44

0.1

04

0.1

76

0.2

04

0.2

02

0.2

0.1

44

0.1

56

0.1

54

0.1

66

0.1

3

0.1

46

0.1

82

0.1

46

0.1

66

0.1

56

0.1

74

0.1

92

0.2

12

0.1

94

0.1

9

0.1

88

0.2

06

0.2

06

0.2

66

0.2

5

0.2

3

Slidin

g

distan

ce (m) 56.5

4862

113.0

972

169.6

459

226.1

945

282.7

431

339.2

917

395.8

403

452.3

89

508.9

376

565.4

862

622.0

348

678.5

834

735.1

321

791.6

807

848.2

293

904.7

779

961.3

265

1017.8

75

1074.4

24

1130.9

72

1187.5

21

1244.0

7

1300.6

18

1357.1

67

1413.7

16

1470.2

64

1526.8

13

1583.3

61

1639.9

1

1696.4

59

Wear

rate

(mm3/

Nm) 5.5

6E

-05

6.9

4E

-05

3.7

E-0

5

2.7

8E

-05

1.6

7E

-05

1.3

9E

-05

7.9

4E

-06

1.3

9E

-05

6.1

7E

-06

5.5

6E

-06

7.5

8E

-06

6.9

4E

-06

4.2

7E

-06

7.9

4E

-06

3.7

E-0

6

1.7

4E

-06

3.2

7E

-06

7.7

2E

-06

7.3

1E

-06

1.1

1E

-05

5.2

9E

-06

6.3

1E

-06

6.0

4E

-06

5.7

9E

-06

2.2

2E

-06

4.2

7E

-06

5.1

4E

-06

2.9

8E

-06

2.8

7E

-06

1.8

5E

-06

Table 4.15(COATED MILD STEEL) (Track radius: 30mm, Speed: 300rpm and Load: 50N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 56

SPECIMEN : B6

LOAD : 10 N

INTIALWT IN gms : 12.910

FINAL WT IN gms : 12.905

WEIGHT LOSS : 0.005

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

4

9

9

9

9

9

7

6

7

6

6

4

4

6

6

4

6

6

6

4

4

4

4

4

3

4

4

4

4

Frict

on

force(

N)

3.1

6.1

5.3

5.4

8.3

8.9

7.8

8

7.7

7.8

7.7

7.5

7.6

7.5

7.6

7.4

7.5

7.6

7.9

7.9

8.2

7.9

8.1

7.9

7.9

7.6

7.6

7.4

7.6

7.5

Temp

eratu

re

28

28

28

28

29

29

29

29

30

30

30

30

31

31

31

32

32

32

33

33

33

33

34

34

34

34

34

35

35

35

Coeffi

cient

of

frictio

n

(COF

)

0.2

9

0.5

9

0.5

1

0.5

2

0.8

1

0.8

7

0.7

6

0.7

8

0.7

5

0.7

6

0.7

5

0.7

3

0.7

4

0.7

3

0.7

4

0.7

2

0.7

3

0.7

4

0.7

7

0.7

7

0.8

0.7

7

0.7

9

0.7

7

0.7

7

0.7

4

0.7

4

0.7

2

0.7

4

0.7

3

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 8.3

3E

-05

0.0

00167

0.0

00222

0.0

00167

0.0

00133

0.0

00111

9.5

2E

-05

6.2

5E

-05

4.6

3E

-05

0.0

0005

3.7

9E

-05

3.4

7E

-05

2.5

6E

-05

2.3

8E

-05

2.7

8E

-05

2.6

E-0

5

1.9

6E

-05

2.3

1E

-05

2.1

9E

-05

2.0

8E

-05

1.5

9E

-05

1.5

2E

-05

1.4

5E

-05

1.3

9E

-05

1.3

3E

-05

9.6

2E

-06

1.2

3E

-05

1.1

9E

-05

1.1

5E

-05

8.3

3E

-05

Table 4.16(COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 10N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 57

SPECIMEN : B7

LOAD : 20 N

INTIALWT IN gms : 12.990

FINAL WT IN gms : 12.988

WEIGHT LOSS : 0.002

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

2

2

9

12

9

12

12

12

12

9

9

7

4

10

9

10

12

10

10

9

9

10

8

9

10

12

12

13

10

12

Frict

on

force(

N)

10.7

12.2

13.4

12.9

15.4

12.1

11.8

12.7

13

13.2

12.7

13

12.4

12.9

13.2

13.4

12.9

13.4

14.8

15.4

14.9

13.9

13.5

14.4

15.4

13.8

14

14.3

14.4

10.7

Temp

eratu

re

28

28

28

29

29

30

30

31

32

33

33

33

33

33

33

34

34

34

34

34

34

34

34

35

35

35

36

36

36

36

Coeffi

cient

of

frictio

n

(COF

)

0.5

25

0.6

0.6

6

0.6

35

0.7

6

0.5

95

0.5

8

0.6

25

0.6

4

0.6

5

0.6

25

0.6

4

0.6

1

0.6

35

0.6

5

0.6

6

0.6

35

0.6

6

0.7

3

0.7

6

0.7

35

0.6

85

0.6

65

0.7

1

0.7

6

0.6

8

0.6

9

0.7

05

0.7

1

0.5

25

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 8.3

3E

-05

4.1

7E

-05

0.0

00111

0.0

00104

6.6

7E

-05

6.9

4E

-05

5.9

5E

-05

5.2

1E

-05

4.6

3E

-05

3.3

3E

-05

3.0

3E

-05

2.0

8E

-05

1.2

8E

-05

2.6

8E

-05

2.2

2E

-05

2.3

4E

-05

2.4

5E

-05

2.0

8E

-05

1.9

7E

-05

1.6

7E

-05

1.5

9E

-05

1.7

E-0

5

1.2

7E

-05

1.3

9E

-05

0.0

00015

1.6

E-0

5

1.5

4E

-05

1.6

4E

-05

1.2

9E

-05

1.3

9E

-05

Table 4.17(COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 20N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 58

SPECIMEN : B8

LOAD : 30 N

INTIALWT IN gms : 12.899

FINAL WT IN gms : 12.890

WEIGHT LOSS : 0.009

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

2

3

3

4

7

7

7

8

8

7

8

7

7

6

6

7

6

7

7

6

7

6

6

7

6

8

7

8

7

Frict

on

force(

N)

8.9

13.3

16.2

17.7

20.4

18.8

18.7

18.9

18.8

19.3

19.8

20.4

19.9

19.3

20.5

20.2

20.1

18.3

19.4

19.6

19

19.9

20.8

19.1

18.3

18.2

17.3

18.7

19

19.3

Temp

eratu

re

24

24

25

25

25

26

28

29

29

30

30

32

32

33

35

35

36

36

37

37

38

38

39

39

39

39

40

40

40

40

Coeffi

cient

of

frictio

n

(COF

)

0.2

9

0.4

36667

0.5

33333

0.5

83333

0.6

73333

0.6

2

0.6

16667

0.6

23333

0.6

2

0.6

36667

0.6

53333

0.6

73333

0.6

56667

0.6

36667

0.6

76667

0.6

66667

0.6

63333

0.6

03333

0.6

4

0.6

46667

0.6

26667

0.6

56667

0.6

86667

0.6

3

0.6

03333

0.6

0.5

7

0.6

16667

0.6

26667

0.6

36667

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 2.7

8E

-05

2.7

8E

-05

2.7

8E

-05

2.0

8E

-05

2.2

2E

-05

2.7

8E

-05

2.3

8E

-05

2.0

8E

-05

2.1

6E

-05

1.9

4E

-05

1.5

2E

-05

1.6

2E

-05

1.2

8E

-05

1.1

9E

-05

9.2

6E

-06

8.6

8E

-06

9.8

E-0

6

7.7

2E

-06

8.7

7E

-06

8.3

3E

-06

6.6

1E

-06

7.5

8E

-06

6.0

4E

-06

5.7

9E

-06

6.6

7E

-06

5.3

4E

-06

7.2

E-0

6

5.9

5E

-06

6.7

E-0

6

5.5

6E

-06

Table 4.18(COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 30N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 59

SPECIMEN : B9

LOAD : 40 N

INTIALWT IN gms : 12.896

FINAL WT IN gms : 12.890

WEIGHT LOSS : 0.006

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

1

2

2

2

3

7

6

4

3

3

4

4

4

6

4

6

6

4

3

6

3

4

14

18

15

14

14

16

20

Frict

on

force(

N)

0.9

2.6

3.8

8.7

10.6

21.5

20.5

24.1

27.5

23

22.1

23.6

29

30.5

25.4

29.6

24.7

24.4

25

22.6

24.8

25.8

25.8

22.2

23.4

21.4

20.4

24.4

24.7

20.5

Temp

eratu

re

29

29

29

29

29

33

35

38

40

40

40

42

42

42

42

42

42

42

42

42

43

43

43

43

44

44

44

44

44

44

Coeffi

cient

of

frictio

n

(COF

)

0.0

175

0.0

6

0.0

9

0.2

125

0.2

6

0.5

325

0.5

075

0.5

975

0.6

825

0.5

7

0.5

475

0.5

85

0.7

2

0.7

575

0.6

3

0.7

35

0.6

125

0.6

05

0.6

2

0.5

6

0.6

15

0.6

4

0.6

4

0.5

5

0.5

8

0.5

3

0.5

05

0.6

05

0.6

125

0.5

075

Slidin

g

distan

ce (m)

94.2

477

188.4

954

282.7

431

376.9

908

471.2

385

565.4

862

659.7

339

753.9

816

848.2

293

942.4

77

1036.7

25

1130.9

72

1225.2

2

1319.4

68

1413.7

16

1507.9

63

1602.2

11

1696.4

59

1790.7

06

1884.9

54

1979.2

02

2073.4

49

2167.6

97

2261.9

45

2356.1

93

2450.4

4

2544.6

88

2638.9

36

2733.1

83

2827.4

31

Wear

rate

(mm3/

Nm) 2.0

8E

-05

1.0

4E

-05

1.3

9E

-05

1.0

4E

-05

8.3

3E

-06

1.0

4E

-05

1.7

9E

-05

1.3

E-0

5

9.2

6E

-06

6.2

5E

-06

5.6

8E

-06

6.9

4E

-06

6.4

1E

-06

5.9

5E

-06

6.9

4E

-06

5.2

1E

-06

6.1

3E

-06

5.7

9E

-06

4.3

9E

-06

3.1

3E

-06

4.9

6E

-06

2.8

4E

-06

3.6

2E

-06

1.0

4E

-05

1.2

5E

-05

1.0

4E

-05

9.2

6E

-06

8.9

3E

-06

1.0

1E

-05

1.1

8E

-05

Table 4.19(COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 40N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 60

SPECIMEN : B10

LOAD : 50 N

INTIALWT IN gms : 12.890

FINAL WT IN gms : 12.882

WEIGHT LOSS : 0.008

PAR

AME

TERS

TIME IN

MINUTES

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

Wear

(µm)

1

9

16

4

14

4

4

3

6

7

6

6

6

3

4

6

7

9

10

12

13

9

14

12

10

12

13

20

18

19

Frict

on

force(

N)

10.3

15.4

11.4

29.3

30.3

35.4

30.4

29.5

25.4

30.3

27.4

30.2

28.7

29.7

26.3

27.4

26.9

25.6

30.1

31.2

26.2

28.5

28.3

34.4

34.1

27.5

29.1

25.7

27.4

27.3

Temp

eratu

re

29

30

31

32

32

33

34

35

36

38

40

42

44

44

44

44

44

45

45

45

45

46

46

46

46

47

47

48

50

50

Coeffi

cient

of

frictio

n

(COF

)

0.2

02

0.3

04

0.2

24

0.5

82

0.6

02

0.7

04

0.6

04

0.5

86

0.5

04

0.6

02

0.5

44

0.6

0.5

7

0.5

9

0.5

22

0.5

44

0.5

34

0.5

08

0.5

98

0.6

2

0.5

2

0.5

66

0.5

62

0.6

84

0.6

78

0.5

46

0.5

78

0.5

1

0.5

44

0.5

42

Slidin

g

distan

ce (m)

94.2

477

188.4

95

282.7

43

376.9

91

471.2

39

565.4

86

659.7

34

753.9

82

848.2

29

942.4

77

1036.7

2

1130.9

7

1225.2

2

1319.4

7

1413.7

2

1507.9

6

1602.2

1

1696.4

6

1790.7

1

1884.9

5

1979.2

2073.4

5

2167.7

2261.9

4

2356.1

9

2450.4

4

2544.6

9

2638.9

4

2733.1

8

2827.4

3

Wear

rate

(mm3/

Nm)

1.7

E-0

5

6.7

E-0

5

7.8

E-0

5

1.7

E-0

5

0.0

0004

1.1

E-0

5

9.5

E-0

6

6.3

E-0

6

9.3

E-0

6

0.0

0001

7.6

E-0

6

6.9

E-0

6

6.4

E-0

6

3.6

E-0

6

4.4

E-0

6

5.2

E-0

6

5.9

E-0

6

7.4

E-0

6

7.9

E-0

6

8.3

E-0

6

8.7

E-0

6

6.1

E-0

6

8.7

E-0

6

6.9

E-0

6

6E

-06

6.4

E-0

6

6.8

E-0

6

1E

-05

8.6

E-0

6

8.9

E-0

6

Table 4.20(COATED MILD STEEL) (Track radius: 30mm, Speed: 500rpm and Load: 50N)

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 61

4.2 GRAPHS:

Fig 4.1 Wear v/s load at 300rpm

Fig 4.2 Wear v/s load at 500rpm

Fig 4.1 and 4.2 shows as the load increase wear also increase but the wear of uncoated specimens are

more when compared to coated specimens.

0

10

20

30

40

50

60

10 20 30 40 50

Wear in

μm

Load in N

Wear v/s load at 300 rpm

COATED

UNCOATED

0

10

20

30

40

50

60

70

80

90

10 20 30 40 50

Wear in

μm

Load in N

Wear v/s load at 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 62

Fig 4.3 COF v/s load at 300rpm

Fig 4.4 COF v/s load at 500rpm

Fig 4.3 and 4.4 shows as the load increase COF decreases

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

10 20 30 40 50

CO

F

Load in N

COF v/s load at 300 rpm

COATED

UNCOATED

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

10 20 30 40 50

CO

F

Load in N

COF v/s load at 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 63

Fig 4.5 Wear v/s Sliding distance at 10N & 300rpm

Fig 4.6 Wear v/s Sliding distance at 20N & 300rpm

0

5

10

15

20

25

30

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wear in

μm

Sliding Distance in m

Wear v/s Sliding distance at 10N & 300 rpm

COATED

UNCOATED

0

5

10

15

20

25

30

35

40

45

50

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wea

r in

μm

Sliding Distance in m

Wear v/s Sliding distance at 20N & 300 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 64

Fig 4.7 Wear v/s Sliding distance at 30N & 300rpm

Fig 4.8 Wear v/s Sliding distance at 40N & 300rpm

0

10

20

30

40

50

60

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wear in

μm

Sliding Distance in m

Wear v/s Sliding distance at 30N & 300 rpm

COATED

UNCOATED

0

10

20

30

40

50

60

70

80

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wea

r in

μm

Sliding Distance in m

Wear v/s Sliding distance at 40N & 300 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 65

Fig 4.9 Wear v/s Sliding distance at 50N & 300rpm

Fig 4.10 Wear v/s Sliding distance at 10N & 500rpm

0

10

20

30

40

50

60

70

80

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wear in

μm

Sliding Distance in m

Wear v/s Sliding distance at 50N & 300 rpm

COATED

UNCOATED

0

5

10

15

20

25

30

35

40

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wea

r in

μm

Sliding Distance in m

Wear v/s Sliding distance at 10N & 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 66

Fig 4.11 Wear v/s Sliding distance at 20N & 500rpm

Fig 4.12 Wear v/s Sliding distance at 30N & 500rpm

0

10

20

30

40

50

60

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wear in

μm

Sliding Distance in m

Wear v/s Sliding distance at 20N & 500 rpm

COATED

UNCOATED

0

10

20

30

40

50

60

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wea

r in

μm

Sliding Distance in m

Wear v/s Sliding distance at 30N & 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 67

Fig 4.13 Wear v/s Sliding distance at 40N & 500rpm

Fig 4.14 Wear v/s Sliding distance at 50N & 500rpm

From graphs 4.5 to 4.14 it is clear that increase sliding distance increases the wear rate and it is also

clear that wear of uncoated specimens are more then the coated specimens

0

10

20

30

40

50

60

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wear in

μm

Sliding Distance in m

Wear v/s Sliding distance at 40N & 500 rpm

COATED

UNCOATED

0

10

20

30

40

50

60

70

80

90

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wea

r in

μm

Sliding Distance in m

Wear v/s Sliding distance at 50N & 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 68

Fig 4.15 Wear rate v/s Sliding distance at 10N & 300rpm

Fig 4.16 Wear rate v/s Sliding distance at 20N & 300rpm

0

0.0001

0.0002

0.0003

0.0004

0.0005

0.0006

0.0007

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wear r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 10N & 300 rpm

COATED

UNCOATED

0

0.00005

0.0001

0.00015

0.0002

0.00025

0.0003

0.00035

0.0004

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wea

r r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 20N & 300 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 69

Fig 4.17 Wear rate v/s Sliding distance at 30N & 300rpm

Fig 4.18 Wear rate v/s Sliding distance at 40N & 300rpm

0

0.00005

0.0001

0.00015

0.0002

0.00025

0.0003

0.00035

0.0004

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wear r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 30N & 300 rpm

COATED

UNCOATED

0

0.00005

0.0001

0.00015

0.0002

0.00025

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wea

r r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 40N & 300 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 70

Fig 4.19 Wear rate v/s Sliding distance at 50N & 300rpm

Fig 4.20 Wear rate v/s Sliding distance at 10N & 500rpm

0

0.000005

0.00001

0.000015

0.00002

0.000025

0.00003

282.74 565.46 848.22 1130.97 1413.71 1696.459

Wear r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 50N & 300 rpm

COATED

UNCOATED

0

0.00002

0.00004

0.00006

0.00008

0.0001

0.00012

0.00014

0.00016

0.00018

0.0002

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wea

r r

ate

Sliding Distance in m

Wear v/s Sliding distance at 10N & 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 71

Fig 4.21 Wear rate v/s Sliding distance at 20N & 500rpm

Fig 4.22 Wear v/s Sliding distance at 30N & 500rpm

0

0.00005

0.0001

0.00015

0.0002

0.00025

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wear r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 20N & 500 rpm

COATED

UNCOATED

0

0.00001

0.00002

0.00003

0.00004

0.00005

0.00006

0.00007

0.00008

0.00009

0.0001

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wea

r r

ate

Sliding Distance in m

Wear rate v/s Sliding distance at 30N & 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 72

Fig 4.23 Wear rate v/s Sliding distance at 40N & 500rpm

Fig 4.24 Wear rate v/s Sliding distance at 50N & 500rpm

From graphs 4.15 to 4.24 it is clear that increase sliding distance increases the wear rate and it is also

$clear that wear of uncoated specimens are more then the coated specimens

0

0.00001

0.00002

0.00003

0.00004

0.00005

0.00006

0.00007

0.00008

0.00009

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wear in

μm

Sliding Distance in m

Wear rate v/s Sliding distance at 40N & 500 rpm

COATED

UNCOATED

0

0.00002

0.00004

0.00006

0.00008

0.0001

0.00012

0.00014

0.00016

0.00018

471.23 942.47 1413.71 1884.95 2356.19 2827.43

Wea

r in

μm

Sliding Distance in m

Wear rate v/s Sliding distance at 50N & 500 rpm

COATED

UNCOATED

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 73

CHAPTER 5

CONCLUSION

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 74

CHAPTER 5

CONCLUSION

Based on the tests carried out to study the effect on wear, Mild Steel coated with

Inconel 718 as explained in the previous pages and within the scope of this investigation

the following conclusion has been drawn.

Coating of Inconel 718 on mild steel is effectively done for the thickness of

200microns.

Wear loss of the specimens decreases effectively when compared to uncoated

specimens. n conduction of different wear tests, on varying load and speed

conditions, the following observations are made:

It is clear that increase in sliding distance increases the wear and it is also

observed that wear of uncoated specimens are more then the coated specimens.

As the load increase COF decreases.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 75

CHAPTER 6

SCOPE FOR FUTURE

WORK

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 76

CHAPTER 6

SCOPE FOR FUTURE WORK

In future, some more experiments can be conducted of the coating of Inconel 718 on mild

steel.

SEM (Scanning Electro Microscope) study of coating can be done to study surface

texture and to get exact coating thickness.

Microstructure analysis can be done to study the structure of coatings.

Vickers micro hardness can be done to compare hardness between coated and

uncoated specimens.

Coating can be done by different coating methods.

Corrosion properties can be found out.

Prediction can be done by using neural network.

STUDY OF DRY SLIDING WEAR BEHAVIOUR OF MILD STEEL COATED

WITH INCONEL 718 2009-2010

Dept. of Mech. Engg, DBIT, Blore-74 77

REFERENCES

[1]. Prince M, Gopalakrishnan P, Duraiselvam Muthukannan, More Satish D, Naveen R

and Natarajan S, “Study of Dry Sliding Wear of Plasma Sprayed Mo-Ni/Cr - Ti-

6Al-4V Tribo Pair”, European Journal of Scientific Research ISSN 1450-216X

Vol.37 No.1 (2009), pp.41-48.

[2]. V.k. Gupta1, S. Ray, O.P. Pandey, “Dry sliding wear characteristicsof 0.13 wt. %

carbon steel”, Materials Science-Poland, Vol. 26, No. 3, 2008

[3]. S. Basavarajappa, G. Handramohan, R.Subramanian, A. Chandrasekar , “Dry sliding

wear behavior of Al 2219/SiC metal matrix composites” , Materials Science-

Poland, Vol. 24, No. 2/1, 2006

[4]. P.R. Gangasani, “Friction and wear characteristic of ductile iron in dry sliding

conditions.” 2003 Keith Millis symposium on ductile cast iron

[5]. B.V. Manoj Kumar and Bikramjit Basu, “Tribochemistry in sliding wear of TiCN–

Ni-based cermets” J. Mater. Res., Vol. 23, No. 5, May 2008