Wear in various industries can lead to downtimes and can cause a huge loss. Hence, it is important for any company to be aware of the different types and causes of wear so that they can avoid them.
One of the most common causes is abrasive wear. It occurs when hard particles or grits are forced against a softer material, which removes material from the surface.
Abrasive Wear
Abrasive wear is one of the most common types of damage that can occur in any industry. This wear can cause a huge amount of problems for machinery and equipment and can be expensive. It can also create safety risks for workers and the general public.
In most cases, abrasive wear can be prevented by choosing the right material for the job and by maintaining your equipment properly. This will allow you to save money and time in the long run.
There are many different types of abrasive wear that can occur, but they are all caused by the interaction between hard particles with the surfaces of the components. This can include abrasive particles that are embedded in the machine parts or loose abrasive pieces that are thrown at the equipment by a fluid or air stream.
The two main types of abrasive wear are called two-body and three-body abrasion. The first type involves a hard surface sliding against a softer one and causing grooves on the softer surface. The second type occurs when particles that are cut from the softer surface are trapped between the two surfaces.
These particles may be introduced from the outside environment, or they may have been formed in the equipment’s lubrication system. The abrasive particles are sometimes also small bits of debris from previous wear on the equipment.
Often, abrasive wear is more difficult to solve than corrosion wear or adhesive wear because of the number of different factors that can affect the damage. This is why it is important to conduct a thorough analysis of the problem before taking any steps to fix it.
This is where abrasive wear testing comes in handy. There are several standard tests that can be performed to measure the wear of a component or its parts during a specified period of time under well-defined conditions.
The test results can be used to determine the abrasive resistance of the components in a given application. This information can then be used to select the best steel materials for a particular application.
Corrosion Wear
Corrosion wear is a form of damage that occurs when the surface of a metal or alloy has been exposed to an oxidizing, acidic or caustic environment. It can be caused by abrasion, chemical or electrochemical reactions, moisture or any other environmental factors that affect the material and cause deterioration of its physical properties.
Corrosive wear is a common problem for fleets as it can significantly reduce the life of their equipment and can result in costly repair bills. However, there are many different ways to solve corrosion wear and reduce its effects on a fleet.
One of the most common types of corrosion is rusting and pitting on metals. This type of corrosion is primarily due to salts from seawater and water vapor. The chemicals that are produced by sewage and industrial pollution are also a major contributor to corrosion in some areas.
The corrosive properties of these salts can cause the metal to lose its structural integrity and even become brittle and softer. This is why it is essential to prevent corrosion of any metal that is near water or is impacted by water vapor.
This can be prevented by keeping the surfaces of the metals dry and avoiding contact with corrosive substances such as water, salt or acidic liquids. Another way to solve corrosion is by using a special coating that can help protect the material from corrosion.
Some materials are more prone to corrosive wear than others, such as aluminium alloys and stainless steels. The reactivity of the lubricant is also an important factor to consider in order to reduce the corrosive effects of the surface.
Moreover, the thickness of the protective film that forms can also be an indicator of the effectiveness of a lubricant. It can be a good idea to incorporate additives such as yttrium powder into commercial lubricants that can increase the reactivity of the lubricant and thus improve corrosion resistance on the surface of the metal.
It is a common mistake for fleets to delay corrosion treatment or simply ignore it until it’s too late. This is a mistake that can cost a lot of money in lost productivity, replacements and repairs.
Adhesive Wear
Adhesive wear is one of the most common forms of wear in lubricant systems. It occurs when two surfaces, such as the inner race of a rolling-element bearing, or the surface of a steel cylinder, adhere to each other locally. This type of wear can occur in both dry and corrosive conditions.
The most important way to prevent this type of wear is by preventing metal-to-metal contact between the two sliding surfaces. This can be achieved by a variety of methods, including a lubricant film, coatings or deposits such as PTFE infusion layers.
Another common method to prevent this type of wear is to ensure the correct amount of adhesive is applied to the intended joint. This can be done through the use of automatic and semi-automatic dispensing systems, as well as manual placement systems.
When the proper amount of adhesive is applied to a joint, the bond will be secure and strong. This means that the surface area will be able to hold up to the load and pressure, which can also help to minimise the risk of equipment failure during operation.
However, insufficient adhesive application can be a problem, as can insufficient bonding time. This can be caused by too much or too little air in the adhesive, as well as insufficient spread to fill the gap between the surfaces of the parts that are being joined.
If this problem is not addressed, the result may be that the bond will fail. There are many different modes of failure in this situation, so it’s important to understand them.
In general, there are three types of break in a material system: substrate failure, adhesive failure or cohesive failure. Knowing these is important in understanding the root cause of a bonding issue and how to resolve it.
Regardless of the cause, adhesive wear can be prevented by using the right lubricant composition that takes into account the application, film thickness, temperature, surface loads and environment. Identifying loading problems during installation and taking the appropriate precautions during operation are other effective ways to reduce the likelihood of this problem occurring.
Diffusion Wear
Different Types and Causes of Wear in Various Industries
Any time two surfaces are sliding, rolling or rubbing against each other, the material on one surface may be damaged or removed. This is called wear and can be controlled by applying lubricants that reduce friction between the two surfaces, thereby protecting them from damage and extending the life of the equipment.
Depending on how wear appears, the process can be divided into three main groups: erosive, abrasive and sliding & rolling wear. There are a number of subgroups within these groups.
Abrasive wear occurs when hard particles come into contact with a machine component, causing deformation or removal of the material. This type of wear is often seen in gears, bearings and pulleys.
The types of abrasive wear vary depending on the source. The sources include abrasive particles, harsh chemicals and cavitation.
Abrasion wear can also occur when a surface is exposed to impact, for example from a wheel on tracks or a ball bearing rolling in a machine. This type of wear can be characterized by cracks forming in the surface, accompanied by pitting.
These cracks are caused by the high stress that is brought about by the relative motion of the components, resulting in plastic deformation. During this deformation the materials start to transfer starting with one surface and then onto the next.
This can result in a significant decrease in the operating efficiency of the equipment. This is why companies need to be able to plan ahead and make sure that they use the right wear parts.
There are a variety of ways to solve this problem, including the use of different lubricants that protect the surfaces against each type of wear. However, some wear problems can only be solved by examining the exact causes of the wear.
The best way to identify the cause of the wear is through a detailed analysis of the particles that are produced during the process. These can be analyzed using imaging and non-imaging techniques, such as dynamic light scattering (DLS), SEM/EDS or AFM microscopy.
