ABRASION RESISTANCE OF MATERIALS Edited by Marcin Adamiak Abrasion Resistance of Materials Edited by Marcin Adamiak Published by InTech Janeza Trdine 9, 51000 Rijeka, Croatia Copyright © 2012 InTech All chapters are Open Access distributed under the Creative Commons Attribution 3.0 license, which allows users to download, copy and build upon published articles even for commercial purposes, as long as the author and publisher are properly credited, which ensures maximum dissemination and a wider impact of our publications. After this work has been published by InTech, authors have the right to republish it, in whole or part, in any publication of which they are the author, and to make other personal use of the work. Any republication, referencing or personal use of the work must explicitly identify the original source. As for readers, this license allows users to download, copy and build upon published chapters even for commercial purposes, as long as the author and publisher are properly credited, which ensures maximum dissemination and a wider impact of our publications. Notice Statements and opinions expressed in the chapters are these of the individual contributors and not necessarily those of the editors or publisher. No responsibility is accepted for the accuracy of information contained in the published chapters. The publisher assumes no responsibility for any damage or injury to persons or property arising out of the use of any materials, instructions, methods or ideas contained in the book. Publishing Process Manager Masa Vidovic Technical Editor Teodora Smiljanic Cover Designer InTech Design Team First published March, 2012 Printed in Croatia A free online edition of this book is available at www.intechopen.com Additional hard copies can be obtained from orders@intechweb.org Abrasion Resistance of Materials, Edited by Marcin Adamiak p. cm. ISBN 978-953-51-0300-4 Contents Chapter 1 Abrasion Resistance of Polymer Nanocomposites – A Review 1 Giulio Malucelli and Francesco Marino Chapter 2 Abrasive Effects Observed in Concrete Hydraulic Surfaces of Dams and Application of Repair Materials 19 José Carlos Alves Galvão, Kleber Franke Portella and Aline Christiane Morales Kormann Chapter 3 Abrasion Resistance of High Performance Fabrics 35 Maja Somogyi Škoc and Emira Pezelj Chapter 4 Numerical Simulation of Abrasion of Particles 53 Manoj Khanal and Rob Morrison Chapter 5 Low Impact Velocity Wastage in FBCs – Experimental Results and Comparison Between Abrasion and Erosion Theories 75 J. G. Chacon-Nava, F. Almeraya-Calderon, A. Martinez-Villafañe and M. M. Stack Chapter 6 Heat and Thermochemical Treatment of Structural and Tool Steels 99 Jan Suchánek Chapter 7 Analysis of Abrasion Characteristics in Textiles 119 Nilgün Özdil, Gonca Özçelik Kayseri and Gamze Süpüren Mengüç Chapter 8 Rubber Abrasion Resistance 147 Wanvimon Arayapranee VI Contents Chapter 9 Effect of Abrasive Size on Wear 167 J. J. Coronado Chapter 10 Abrasion Resistance of Cement-Based Composites 185 Wei-Ting Lin and An Cheng 1 Abrasion Resistance of Polymer Nanocomposites – A Review Giulio Malucelli and Francesco Marino Politecnico di Torino, DISMIC Italy 1. Introduction In order to be suitable for tribological applications, polymeric materials, which can usually exhibit mechanical strength, lightness, ease of processing, versatility and low cost, together with acceptable thermal and environmental resistances, have to show good abrasion and wear resistance. This target is not easy to achieve, since the viscoelasticity of polymeric materials makes the analysis of the tribological features and the processes involved in such phenomena quite complicated. Indeed, it is well-known that an improvement of the mechanical properties can be effectively achieved by including “small” inorganic particles in the polymer matrices (Dasari et al., 2009). For applications taking place in hard working conditions, such as slide bearings, the development of composite materials, which possess a high stiffness, toughness and wear resistance, becomes crucial. On the one hand, the extent of the reinforcing effect depends on the properties of composite components, and on the other hand it is strongly affected by the microstructure represented by the filler size, shape, homogeneity of distribution/dispersion of the particles within the polymer, and filler/matrix interface extension. This latter plays a critical role, since the composite material derives from a combination of properties, which cannot be achieved by either the components alone. Thus it is generally expected that the characteristics of a polymer, added of a certain volume fraction of particles having a certain specific surface area, are more strongly influenced when very small particles (nanofillers), promoting an increased interface within the bulk polymer, are used (Bahadur, 2000; Chen et al., 2003; Karger-Kocsis & Zhang, 2005; Li et al., 2001; Sawyer et al., 2003). However, this happens only when a high dispersion efficiency of the nanoparticles within the polymer matrix is assessed: indeed, nanoparticles usually tend to agglomerate because of their high specific surface area, due the adhesive interactions derived from the surface energy of the material. In particular, the smaller the size of the nanoparticles, the more difficult the breaking down of such agglomerates appears, so that their homogeneous distribution within the polymer matrix is compromised. As a consequence, the development of nanocomposites showing high tribological features requires a deep investigation on their micro-to-nanostructure, aiming to find synergistic mechanisms and reinforcement effects exerted by the nanofillers (Burris et al., 2007). Abrasion Resistance of Materials 2 In addition, the way in which nanofillers can improve the tribological properties of polymers depends on the requirement profile of the particular application, i.e. the friction coefficient and the wear resistance cannot be considered as real material properties, since they depend on the systems in which these materials have to function. In particular, such applications as brake pads or clutches usually require a high friction coefficient and, at the same time, a low wear resistance; however, in other circumstances (like in the case of gears or bearings, acting as smooth metallic counterparts under dry sliding conditions) the development of polymer composites having low friction and wear properties is strongly needed. The abrasion performances of polymeric materials depend on several factors, such as the wear mechanisms involved, the abrasive test method used, the bulk and surface properties of the tested specimens, Many papers reported in the literature focus on the investigation on the physical processes involved in abrasive wear of a wide variety of polymers; the obtained results demonstrate that two very different mechanisms of wear may occur in polymers, namely cohesive and interfacial wear processes, as schematically shown in Figure 1. Fig. 1. Schematic representation of cohesive and interfacial wear processes (Adapted from Briscoe & Sinha, 2002) In the cohesive wear processes, such as abrasion wear, fatigue wear and fretting, which mainly depend on the mechanical properties of the interacting materials, the frictional work involves quite large volumes close to the interface, either exploiting the interaction of surface forces and the consequent traction stresses or through the geometric interlocking exerted by the interpenetrating contacts. Contact stresses and contact geometry represent two key parameters that determine the extent of such surface zone. On the other hand, the frictional work in interfacial wear processes (like transfer wear, chemical or corrosive wear) is dissipated in much thinner zones and at greater energy [...]... mechanical properties of compressive strength, splitting tensile strength and grip Considering the results of the 20 Abrasion Resistance of Materials laboratory were selected for field application the concretes with contents of 2.5 and 5.0% Besides the concretes with addition of recycled materials were applied in field The materials used in the field were examined in tests of abrasion resistance of concrete... of wear resistance Zhou and coworkers investigated the tribological behaviour of Nylon 6/Montmorillonite clay nanocomposites: the poor abrasion resistance exhibited by the nanocomposites was attributed to the presence of defects at the clay/polymer interface, resulting in lower wear resistance of the polymer matrix as the nanofiller content increased (Zhou et al., 2009) 10 Abrasion Resistance of Materials. .. Results of testing of abrasion resistance of the RM with concrete with steel fibers (a) Specimen after test (b) 3D schematic graph of wear occurred in the abrasion resistance test (underwater method) 28 Abrasion Resistance of Materials Horszczaruk (2009) conducted a study with high performance concrete (HPC) and high performance fiber-reinforced concrete (HPFCR) to analyze performance and hydraulic abrasion. .. (b) Fig 5 Results of testing of abrasion resistance of the RM with epoxy mortar (a) Specimen after test (b) 3D schematic graph of wear occurred in the abrasion resistance test (underwater method) 30 (cm ) 20 Abrasive Effects Observed in Concrete Hydraulic Surfaces of Dams and Application of Repair Materials 27 Altura arbitrária (hmáx.do CP = 10 cm) In Fig 6, shows the performance of the system substrate|polymer... depths of 2 and 3 m (ACI, 1999) 2.3 The main factors affecting the resistance of concrete abrasion The main factors affecting the abrasion resistance of concrete are the environmental conditions and dosing of aggregates, concrete strength, the mix ratio, the use of special cement, the use of supplementary materials, such as adding fiber and fly ash Two other factors have an important effect on the abrasion. .. abrasion resistance, surface finish and curing conditions (Horszczaruk, 2005) The compressive strength proved to be one of the most important factors that correlate with the abrasion resistance of concrete The compressive strength does not influence the abrasion resistance however is verified a correlation between them, if one is high; the other tends to be too 22 Abrasion Resistance of Materials. .. The samples subjected to abrasion tests were evaluated according to the wear surface Is shown in Fig 2a, overview of the spillway It is observed that the wall of the gate shows signs of erosion (highlighted) Is shown in Fig 2b, defect in a slab of the spillway caused by abrasion 24 Abrasion Resistance of Materials (a) (b) Fig 2 (a) Spillway dam presented deterioration by abrasion (b) Defects in the... inappropriate use of materials and physical and chemical effects of the environment where it operates The immediate consequence is the anticipated need of maintenance and execution of repairs (Galvão et al, 2011) In the case of hydraulic structures of concrete, one of the main forms of degradation is related to abrasive processes In general, the erosion caused by surface wear of the hydraulic structures of concrete,... Fig 6 Results of testing of abrasion resistance of the RM with polymer mortar (a) Specimen after test (b) 3D schematic graph of wear occurred in the abrasion resistance test (underwater method) Altura arbitrária (hmáx.do CP = 10 cm) The effect of abrasion on the test substrate system|concrete with steel fibers was also not very pronounced The mass loss was more intense in the region of RC, as shown... this behaviour was attributed to the lubricating capability of the nanofillers 6 Abrasion Resistance of Materials Zhang et al investigated the effect of nano-silica particles on the tribological behaviour of PEEK: silica nanoparticles were compounded with the polymer by means of a ball milling technique (Zhang et al., 2008) The wear resistance of PEEK was significantly improved after incorporating nano-SiO2 . ABRASION RESISTANCE OF MATERIALS Edited by Marcin Adamiak Abrasion Resistance of Materials Edited by Marcin Adamiak Published. presence of defects at the clay/polymer interface, resulting in lower wear resistance of the polymer matrix as the nanofiller content increased (Zhou et al., 2009). Abrasion Resistance of Materials. the presence of 2.5 wt.% nanoparticles, with respect to the neat PEEK: this behaviour was attributed to the lubricating capability of the nanofillers. Abrasion Resistance of Materials 6