Three-Body Abrasive Wear Performance of Carbon Steel Wear-Resistant Surfacings

Literature Overview

This study, published in Hot Working Technology in 2015 by researchers from Yunnan Electromechanical Vocational and Technical College, investigates the three-body abrasive wear behavior of three different carbon steel wear-resistant surfacing layers. Three-body abrasive wear, where loose abrasive particles are trapped between two sliding surfaces, is one of the most common wear mechanisms encountered in industrial equipment such as crushers, conveyors, and grinding mills. Understanding how different surfacing processes and post-weld heat treatments affect wear resistance under these conditions is essential for material selection and process optimization.

Experimental Design and Key Results

The researchers tested three surfacing layers produced by different welding methods—electrode surfacing and flux-cored wire surfacing—under three-body abrasive wear conditions. The wear tests varied load and sliding velocity, and a low-temperature tempering treatment was applied to some specimens for comparison with the as-welded condition.

Test Variable	Effect on Wear Loss	Mechanism
Increasing load	Wear loss increases	Greater plastic deformation and material removal
Increasing sliding velocity	Wear loss decreases	Higher temperature promotes work hardening and oxide film formation
Low-temperature tempering	Wear loss significantly increases	Softening of matrix reduces resistance to abrasion
Flux-cored wire vs. electrode	Flux-cored wire superior	Better alloying and microstructural refinement

The finding that wear loss decreases with increasing sliding velocity is counterintuitive but well-explained by the formation of protective oxide films at higher temperatures. As the sliding velocity increases, the frictional heat raises the contact temperature, which accelerates the formation of iron oxide layers that protect the underlying metal. This self-lubricating effect can reduce wear loss even as the mechanical energy input increases.

Microstructural and Wear Mechanism Analysis

All three surfacing layers exhibited similar wear mechanisms, primarily consisting of abrasive grooving, micro-cutting, and plastic deformation. The flux-cored wire surfacing layer, however, demonstrated significantly better wear resistance than the electrode surfacing layer. This superiority can be attributed to the flux-cored wire's ability to deliver more consistent and controllable alloy addition, resulting in a more homogeneous microstructure with better-distributed carbides.

The low-temperature tempering treatment, typically performed to relieve residual stresses, had the unintended consequence of softening the matrix and reducing wear resistance. This highlights an important engineering trade-off: while tempering improves toughness and reduces cracking susceptibility, it can compromise wear resistance in applications where hardness is the primary requirement. Engineers must carefully balance these competing demands based on the specific service conditions.

Engineering Practice Insights

This study provides practical guidance for engineers selecting surfacing materials and processes for three-body abrasive wear applications. The key recommendations are:

Flux-cored wire surfacing should be preferred over electrode surfacing when wear resistance is the primary concern, as it produces more uniform and refined microstructures.
Post-weld heat treatment must be carefully considered; low-temperature tempering may not be appropriate for wear-critical applications where maximum hardness is required.
Operating conditions such as load and sliding velocity should be optimized to take advantage of the self-lubricating oxide film effect at higher velocities.
Wear testing under actual service conditions is essential, as laboratory results may not fully capture the complexity of real-world three-body abrasive environments.

The study also demonstrates the importance of understanding wear mechanisms rather than simply comparing hardness values. Two materials with similar hardness can exhibit vastly different wear performance depending on their microstructural characteristics and the specific wear conditions. A comprehensive approach that considers microstructure, hardness, toughness, and service environment is essential for successful surfacing material selection.

This research underscores the value of systematic wear testing in guiding engineering decisions. By understanding the fundamental wear mechanisms and the factors that influence them, engineers can make more informed choices about surfacing materials and processes, ultimately extending equipment life and reducing maintenance costs in abrasive service environments.