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Ann Zammit
Stephen C Abela
University of Malta
University of Malta
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Lothar Wagner
Mansour Mhaede
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Wear
journal homepage: www.elsevier.com/locate/wear
Department of Metallurgy and Materials Engineering, Faculty of Engineering, University of Malta, Msida MSD 2080, Malta
Institute of Materials Science and Engineering, Clausthal University of Technology, Agricolastrasse 6, D-38678 Clausthal-Zellerfeld, Germany
a r t i c l e i n f o
abstract
Article history:
Received 6 August 2012
Received in revised form
10 December 2012
Accepted 13 December 2012
Available online 23 December 2012
Wear and fatigue properties of power transmission components are usually improved by various
surface engineering processes. One surface modication process is shot peening which is generally
carried out to improve bending fatigue. However there are contrasting studies meant to investigating
whether shot peening actually increases the sliding wear resistance of austempered ductile iron (ADI).
Unlubricated wear tests were conducted on ground ADI and shot peened ADI pins. Hardness
measurements of the worn ADI surfaces showed a 19% increase in hardness after testing at low loads,
possibly due to strain hardening and frictional heating. Metallography of the worn surfaces showed
a distorted microstructure at the surface, indicative of surface ow. On the other hand, samples tested
at high loads showed a 73% increase in hardness. A white non-etchable layer which was identied
as untempered martensite formed upon cooling of wear test samples. Calculation of the wear factors
and friction coefcients showed that shot peening does not improve the wear resistance. This has been
attributed to the fact that the potential advantages resulting from the higher hardness at the surface,
stress-induced austenite to martensite transformation and the residual compressive stresses of the shot
peened specimens are counteracted by the induced surface roughness.
& 2012 Elsevier B.V. All rights reserved.
Keywords:
Austempered ductile iron
Sliding wear
Shot peening
Phase transformation
1. Introduction
Careful selection of austempering heat treatment parameters
applied to ductile iron results in a variety of microstructures and a
correspondingly wide range of bulk mechanical properties. This
renders austempered ductile iron (ADI) a potential alternative to
steel, having comparable strength and toughness, lower density
and greater damping capacity, combined with excellent castability.
ADI is in fact suitable for automotive components such as crank
shafts, connecting rods and transmission gears [1,2].
It has been reported [36] that the unique wear behaviour of
ADI is affected by the presence of surface graphite nodules as well
as the ability of the retained austenite, which is metastable at
room temperature, to transform to martensite when loaded.
Straffelini et al. [4] show that ADI exhibited a lower coefcient
of friction and wear coefcient than that of nitrided steel during
dry rolling-sliding wear testing. The authors attribute this to the
smearing of graphite on to the surface which in turn served as
a solid lubricant between the two wear surfaces. Straffelini et al. [4]
determined the wear mechanism occurring during sliding of
austempered ductile iron by using the wear-mechanism maps
described by Lim and Ashby [7]. The latter authors gave graphical
0043-1648/$ - see front matter & 2012 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.wear.2012.12.027
830
After heat treatment of both pins and disks, the surfaces were
ground up to a mean surface roughness Ra of 0.2 mm. After
grinding, half of the pins were shot peened. Shot peening was
carried out using S330 shots, with an Almen intensity of
0.38 mmA up to 100% coverage. The stand-off distance was
90 mm while the angle of impingement was set at 901. The
surface roughness Ra of the shot peened pins was measured to
be 3.7 mm.
2.3. Characterisation
Table 2
Chemical composition of the steel reference disks.
2. Experimental procedure
2.1. Material and processing
Test pins of 5 mm diameter used for the pin-on-disk wear
testing were machined from ductile iron keel blocks, having the
composition shown in Table 1. After machining, samples were
austenitised at 900 72 1C, and then rapidly quenched in a salt
bath at 36075 1C and held for 1 h. The samples were then air
cooled to room temperature. These austempering parameters
were optimised in a previous study [20]. Samples were coated
using a dedicated paint (SEMCO Zir H) to prevent decarburisation
during the austempering process.
Test disks of 90 mm diameter were made out of D2 tool steel
of chemical composition shown in Table 2 and heat treated to a
hardness of 61 HRC. The heat treatment cycle consisted of preheating, followed by austenitising at a temperature of 1025 1C
and then quenching using nitrogen at a pressure of 5 bar. After
that, the disks were tempered at a temperature of 190 1C for 3 h.
2.2. Surface treatment
Element
Cr
Mo
Mn
Si
Fe
Composition (wt%)
11.8
1.55
0.8
0.8
0.4
0.3
Bal
Table 1
Chemical composition of the keel blocks.
Element
Si
Cu
Ni
Mn
Mg
Al
Fe
Composition (wt%)
3.26
2.36
1.63
1.58
0.24
0.011
0.057
0.024
0.006
Bal
831
Table 3
Tribological test conditions.
Specimen
identication
Surface
condition
Nominal applied
pressure (MPa)
G2.5
SP2.5
G10
SP10
Ground ADI
Shot peened ADI
Ground ADI
Shot peened ADI
2.5
10
Fig. 2. SP microstructure.
832
of the bulk; 440 and 370 HV, respectively (Fig. 5) for tested G
specimens. The thickness of this hardened layer is around
100 mm. This was also observed by Refaey et al. and Islam et al.
[24,25] who state that this increase in hardness is due to strain
hardening of the ausferritic matrix at the surface region which
predominates over any frictional heating effect. As a result of this
plastic deformation, the material is stronger and causes surface
ow and the microstructure to distort. Fig. 6 shows the distorted
microstructure of a section taken across the worn surface after
testing with the lower load.
It is noted that the hardness of SP specimens decreases after
wear testing, from 535 to 450 HV. This is probably due to the
removal of part of the shot peened layer during the wear test, or
tempering of the martensite which was formed during the shot
peening process (Fig. 3).
On the other hand, the microhardness at the surface of specimens tested at the higher load is over 600 HV (Fig. 5). This
indicates a phase transformation to a high hardness phase.
Micrographs show that a white non-etchable phase is present at
the surface of the specimens tested with the higher load (Fig. 7).
When the two surfaces slide over each other, most of the work
done against friction is converted into heat, causing a general rise
Fig. 6. Microstructure just below the worn surface shows distortion and surface
ow.
833
834
hence lowers the frictional resistance [30]. This contrasts with the
results shown in the present work. One may argue that the
negative impact of the rougher surface, was in this study more
dominant than the benecial inuence of any phase transformation (Figs. 2 and 3), and compressive residual stresses present at
the surface of SP specimens [15]. Analysis of the surface roughness of the shot peened wear test samples used in the two studies
may throw more light on this apparent inconsistency.
Fig. 14 also shows that a lower CoF was recorded when testing
specimens at a higher applied load. High applied pressure
promotes the phase transformation of retained austenite to
martensite, a harder and load bearing phase. It is known that
friction properties are generally improved when the hardness of
the surface is increased. As explained by Mokhtar et al. [31], cold
weld junctions formed when hard phases like martensite are
present are relatively easy to break, hence lowering the adhesion
of the surfaces and the frictional resistance. Also, martensite has
better thermal properties, providing better heat dissipation leading to a reduction in the CoF [32,33].
On the other hand, under the action of low applied loads, no
martensite formation is observed. The asperities of the harder
disk indent into the softer ausferritic structure of the pin causing
plastic deformation and strong cold-welded junctions are formed.
Frictional sliding resistance to motion is thus higher due to the
larger force required to shear these welded junctions [31].
3.6. Wear mechanism
835
4. Conclusions
In this study, unlubricated sliding wear tests were carried out
to determine the effect of shot peening (SP) on the tribological
behaviour of CuNi alloyed austempered ductile iron. Pin-on-disk
tests were conducted on ground ADI, and shot peened ADI
specimens using two nominal applied loads. The results of the
present work are summarised as follows:
(1) Shot peening of ADI results in an increase in surface roughness and hardness, together with austenite to martensite
transformation.
(2) Specimens tested at the lower load showed a distorted
microstructure just below the wear scar indicative of surface
ow. An increase in surface hardness of 19% was noted on
these surfaces after wear tests. On the other hand, untempered martensite was observed on the surface of specimens
Fig. 17. SEM micrographs of debris collected from wear tests; (a) ADI 10 MPa, (b) SP 10 MPa.
836
Acknowledgements
The authors would like to thank Mr. Mark Joseph Zerafa
(B.Eng.(Hons.)) for his contribution in machining and testing of
specimens.
In addition, the authors would like to acknowledge the
positive impact of ERDF funding and the purchase of the testing
equipment through the project: Developing an Interdisciplinary
Material Testing and Rapid Prototyping R&D Facility (Ref. no. 012).
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