A numerical methodology for predicting tool wear in Friction Stir Welding

Hasan, Ahmed; Bennett, Chris; Shipway, P.H.; Cater, S.; Martin, J.

doi:10.1016/j.jmatprotec.2016.11.009

The effect of frequency on both the debris and the development of the tribologically transformed structure during fretting wear of a high strength steel (2019)
Journal Article
Kirk, A. M., Shipway, P. H., Sun, W., & Bennett, C. J. (2019). The effect of frequency on both the debris and the development of the tribologically transformed structure during fretting wear of a high strength steel. Wear, 426-427(Part A), 694-703. https://doi.org/10.1016/j.wear.2018.12.035

It is well established that damage to the first bodies in fretting wear gives rise to a hard and brittle tribologically transformed structure (TTS) which can influence both wear and fatigue. While the existence and significance of TTS has been establ... Read More about The effect of frequency on both the debris and the development of the tribologically transformed structure during fretting wear of a high strength steel.

Debris development in fretting contacts: debris particles and debris beds (2019)
Journal Article
Kirk, A., Shipway, P., Sun, W., & Bennett, C. (2019). Debris development in fretting contacts: debris particles and debris beds. Tribology International, https://doi.org/10.1016/j.triboint.2019.01.051

In this study, the formation and destruction of compacted beds of oxidized debris particles are investigated. Fretting tests of steel specimens were conducted, employing a cylinder-on-flat geometry with displacement amplitude being varied. The debris... Read More about Debris development in fretting contacts: debris particles and debris beds.

Microstructural characterisation of Tristelle 5183 (Fe-21%Cr-10%Ni-7.5%Nb-5%Si-2%C in wt%) alloy powder produced by gas atomisation (2018)
Journal Article
Carrington, M., Daure, J., Ratia, V., Shipway, P., McCartney, D., & Stewart, D. (2019). Microstructural characterisation of Tristelle 5183 (Fe-21%Cr-10%Ni-7.5%Nb-5%Si-2%C in wt%) alloy powder produced by gas atomisation. Materials and Design, 164, Article 107548. https://doi.org/10.1016/j.matdes.2018.107548

Nitrogen gas atomised powders of the hardfacing alloy Tristelle 5183 (Fe-21%Cr-10%Ni-7%Nb-5%Si-2%C in wt%) were sieved into different particle size ranges and their microstructures have been investigated. Powder particles larger than approximately 53... Read More about Microstructural characterisation of Tristelle 5183 (Fe-21%Cr-10%Ni-7.5%Nb-5%Si-2%C in wt%) alloy powder produced by gas atomisation.

The effect of temperature on sliding wear of self-mated HIPed Stellite 6 in a simulated PWR water environment (2018)
Journal Article
Ratia, V., Zhang, D., Carrington, M., Daure, J., McCartney, D., Shipway, P., & Stewart, D. (2019). The effect of temperature on sliding wear of self-mated HIPed Stellite 6 in a simulated PWR water environment. Wear, 420-421, 215-225. https://doi.org/10.1016/j.wear.2018.09.012

Cobalt-based Stellite alloys are widely used in the primary circuit of pressurized water reactors (PWR) to protect valve surfaces against wear and galling in a corrosive environment. In this study, self-mated sliding wear of HIP-consolidated (Hot Iso... Read More about The effect of temperature on sliding wear of self-mated HIPed Stellite 6 in a simulated PWR water environment.

A comparison of the galling wear behaviour of PVD Cr and electroplated hard Cr thin films (2018)
Journal Article
Daure, J., Carrington, M., Shipway, P., McCartney, D., & Stewart, D. (in press). A comparison of the galling wear behaviour of PVD Cr and electroplated hard Cr thin films. Surface and Coatings Technology, https://doi.org/10.1016/j.surfcoat.2018.06.070

Electroplated hard chromium (EPHC) is used in many industries as a wear and corrosion resistant coating. However, the long term viability of the electroplating process is at risk due to legislation regarding the toxic chemicals used. The physical vap... Read More about A comparison of the galling wear behaviour of PVD Cr and electroplated hard Cr thin films.

Corrosion of cast Stellite-3 analogue in simulated PWR conditions (2018)
Journal Article
Karimi, G., Shipway, P., Stewart, D., & Hussain, T. (2018). Corrosion of cast Stellite-3 analogue in simulated PWR conditions. Corrosion Science, 140, 402-411. https://doi.org/10.1016/j.corsci.2018.05.023

© 2018 Elsevier Ltd Wear resistant alloys are required for deployment in pressurised water reactor primary circuits and in this context, the corrosion behaviour of a cast cobalt-based alloy following exposure for 30 days in lithiated water at 300 °C... Read More about Corrosion of cast Stellite-3 analogue in simulated PWR conditions.

Process parameter optimisation of laser clad iron based alloy: Predictive models of deposition efficiency, porosity and dilution (2018)
Journal Article
Reddy, L., Preston, S. P., Shipway, P., Davis, C., & Hussain, T. (2018). Process parameter optimisation of laser clad iron based alloy: Predictive models of deposition efficiency, porosity and dilution. Surface and Coatings Technology, 349, 198-207. https://doi.org/10.1016/j.surfcoat.2018.05.054

As a candidate coating material for heat-exchanger surfaces in commercial power generation boiler, an amorphous/glass forming Fe-Cr-B alloy NanoSteel SHS 7170 was deposited by a 2 kW fibre laser onto a boiler grade steel substrate (15Mo3). A comprehe... Read More about Process parameter optimisation of laser clad iron based alloy: Predictive models of deposition efficiency, porosity and dilution.

The role of a thermally sprayed CuNiIn underlayer in the durability of a dry-film lubricant system in fretting: a phenomenological model (2018)
Journal Article
Barman, K., Shipway, P., Voisey, K., & Pattinson, G. (2018). The role of a thermally sprayed CuNiIn underlayer in the durability of a dry-film lubricant system in fretting: a phenomenological model. Tribology International, 123, https://doi.org/10.1016/j.triboint.2018.03.018

Dry film lubricant coatings (DFL) are employed to reduce friction and damage in highly loaded contacts. Metallic underlayers, e.g. CuNiIn, can be beneficial however, there is no detailed explanation of the mechanism. This work investigates the effect... Read More about The role of a thermally sprayed CuNiIn underlayer in the durability of a dry-film lubricant system in fretting: a phenomenological model.

Effects of surface roughness on local friction and temperature distributions in a steel-on-steel fretting contact (2018)
Journal Article
Qin, W., Jin, X., Kirk, A., Shipway, P., & Sun, W. (2018). Effects of surface roughness on local friction and temperature distributions in a steel-on-steel fretting contact. Tribology International, 120, https://doi.org/10.1016/j.triboint.2018.01.016

It has generally been assumed that initial surface roughness has significant influences on local frictional shear stresses and flash temperatures in fretting contacts. However, since these hypotheses are difficult to directly measure, the frictional... Read More about Effects of surface roughness on local friction and temperature distributions in a steel-on-steel fretting contact.

An experimental study on the key fretting variables for flexible marine risers (2017)
Journal Article
O’Halloran, S., Harte, A., Shipway, P., & Leen, S. (2018). An experimental study on the key fretting variables for flexible marine risers. Tribology International, 117, https://doi.org/10.1016/j.triboint.2017.07.032

This paper presents an experimental investigation into the effects of contact conformity, contact pressure and displacement amplitude on the gross-slip fretting behaviour grease-lubricated cylinder-on-flat contacts in the context of flexible marine r... Read More about An experimental study on the key fretting variables for flexible marine risers.

The effect of coating architecture and defects on the corrosion behaviour of a PVD multilayer Inconel 625/Cr coating (2017)
Journal Article
Daure, J., Voisey, K., Shipway, P., & Stewart, D. (2017). The effect of coating architecture and defects on the corrosion behaviour of a PVD multilayer Inconel 625/Cr coating. Surface and Coatings Technology, 324, https://doi.org/10.1016/j.surfcoat.2017.06.009

This paper investigates the effect of substrate surface finish and deposition conditions of PVD multilayer Inconel 625/Cr coatings on their ability to act as a corrosion-barrier. The corrosion-barrier performance of the coatings was characterized by... Read More about The effect of coating architecture and defects on the corrosion behaviour of a PVD multilayer Inconel 625/Cr coating.

The role of temperature and frequency on fretting wear of a like-on-like stainless steel contact (2017)
Journal Article
Jin, X., Shipway, P., & Sun, W. (2017). The role of temperature and frequency on fretting wear of a like-on-like stainless steel contact. Tribology Letters, 65, Article 77. https://doi.org/10.1007/s11249-017-0858-0

The influences of environmental temperature and fretting frequency on the mechanisms and rates of wear in a like-on-like 304 stainless steel contact were examined, and mainly attributed to changes in the mechanical response of the bulk material and t... Read More about The role of temperature and frequency on fretting wear of a like-on-like stainless steel contact.

Tribology: Friction and wear of engineering materials (2017)
Book
Hutchings, I., & Shipway, P. (2017). Tribology: Friction and wear of engineering materials. (2nd). Butterworth-Heinemann

© 2017 Ian Hutchings and Philip Shipway. Published by Elsevier Ltd. All rights reserved. Tribology: Friction and Wear of Engineering Materials, Second Edition covers the fundamentals of tribology and the tribological response of all classes of materi... Read More about Tribology: Friction and wear of engineering materials.

Effect of test conditions on the temperature at which a protective debris bed is formed in fretting of a high strength steel (2017)
Journal Article
Hayes, E., & Shipway, P. (2017). Effect of test conditions on the temperature at which a protective debris bed is formed in fretting of a high strength steel. Wear, 376-377(B), https://doi.org/10.1016/j.wear.2017.01.057

It is well known that mechanisms and rates of fretting wear of many metals are dependent upon the temperature of the environment; specifically, it is known that a transition temperature exists, above which the debris forms a protective bed in the con... Read More about Effect of test conditions on the temperature at which a protective debris bed is formed in fretting of a high strength steel.

Sliding wear analysis of cobalt based alloys in nuclear reactor conditions (2017)
Journal Article
McCarron, R., Stewart, D., Shipway, P., & Dini, D. (2017). Sliding wear analysis of cobalt based alloys in nuclear reactor conditions. Wear, 376-377(B), https://doi.org/10.1016/j.wear.2016.12.018

The study of the wear behaviour of cobalt based alloys in nuclear reactor environmental conditions is the focus of this work. The alloys are used in components within reactors due to their excellent wear and corrosion resistance and their high hardne... Read More about Sliding wear analysis of cobalt based alloys in nuclear reactor conditions.

HVOF and laser cladded Fe-Cr-B coating in simulated biomass combustion: microstructure and fireside corrosion (2017)
Journal Article
Reddy, L., Shipway, P., Davis, C., & Hussain, T. (in press). HVOF and laser cladded Fe-Cr-B coating in simulated biomass combustion: microstructure and fireside corrosion. Oxidation of Metals, https://doi.org/10.1007/s11085-017-9774-9

Biomass is often considered as a low carbon alternative to fossil fuels in the power industry. However the heat exchangers in biomass plants can suffer from chloride based aggressive fireside corrosion. A commercially available amorphous Fe-Cr-B allo... Read More about HVOF and laser cladded Fe-Cr-B coating in simulated biomass combustion: microstructure and fireside corrosion.

Evolution of damage in MoS2-based dry film lubricants (DFLs) in fretting wear – the effect of DFL thickness and contact geometry (2017)
Journal Article
Barman, K., Shipway, P., Voisey, K., & Pattinson, G. (2017). Evolution of damage in MoS2-based dry film lubricants (DFLs) in fretting wear – the effect of DFL thickness and contact geometry. Progress in Organic Coatings, 105, https://doi.org/10.1016/j.porgcoat.2016.12.022

Dry film lubricant (DFL) coatings are widely used to reduce coefficients of friction and damage in highly loaded contacts. This work investigates the behaviour of a commercially available MoS2-based DFL in a cylinder-on-flat contact geometry with a f... Read More about Evolution of damage in MoS2-based dry film lubricants (DFLs) in fretting wear – the effect of DFL thickness and contact geometry.

Evolution of plasticity-based wear damage in gross sliding fretting of a Ti-6Al-4V non-conforming contact (2017)
Journal Article
Mohd Tobi, A., Sun, W., & Shipway, P. (in press). Evolution of plasticity-based wear damage in gross sliding fretting of a Ti-6Al-4V non-conforming contact. Tribology International, 113, https://doi.org/10.1016/j.triboint.2017.01.010

This paper examines the evidence for a plasticity based wear mechanism in the fretting wear of Ti-6Al-4V. Driven by near-surface plastic strain accumulation, the generation of wear debris evolves from coarse metallic debris towards loose fine oxide d... Read More about Evolution of plasticity-based wear damage in gross sliding fretting of a Ti-6Al-4V non-conforming contact.

Investigation on the plasticity accumulation of Ti-6Al-4V fretting wear by decoupling the effects of wear and surface profile in finite element modelling (2016)
Journal Article
Tobi, A. M., Sun, W., & Shipway, P. (in press). Investigation on the plasticity accumulation of Ti-6Al-4V fretting wear by decoupling the effects of wear and surface profile in finite element modelling. Tribology International, https://doi.org/10.1016/j.triboint.2016.12.009

A finite-element-based wear modelling methodology and a computational device for decoupling wear effects is presented in this study. The decoupling of wear effects facilitates the capture of plasticity accumulation on a particular wear-scarring profi... Read More about Investigation on the plasticity accumulation of Ti-6Al-4V fretting wear by decoupling the effects of wear and surface profile in finite element modelling.

A numerical methodology for predicting tool wear in Friction Stir Welding (2016)
Journal Article
Hasan, A., Bennett, C., Shipway, P., Cater, S., & Martin, J. (2017). A numerical methodology for predicting tool wear in Friction Stir Welding. Journal of Materials Processing Technology, 241, https://doi.org/10.1016/j.jmatprotec.2016.11.009

A novel methodology for predicting tool wear in FSW based on a CFD model, coupled with a modified Archard equation, is presented considering the effect of the deformation of the highly viscous flow around the tool on tool wear. A validation process... Read More about A numerical methodology for predicting tool wear in Friction Stir Welding.

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