DOI: https://doi.org/10.15587/1729-4061.2018.140984

Analysis of the properties of antifriction composites based on aluminum alloy's grinding waste

Tetiana Roik, Oleg Gavrish, Volodimir Oliynik, Iuliia Vitsiuk

Abstract


We developed antifriction composites based on regenerated grinding waste of AM4.5Kd aluminum alloy with the addition of МоS2 solid lubricant intended for work in contact pairs of post-printing machines, such as folder-gluing machines and machines for pasting elements into packaging.

Analysis of the structure of the new composite showed that alloying elements of the metal base form strengthening phases, which are evenly distributed in the matrix without segregation clusters. This contributes to an increase in structural strength. Molybdenum disulfide provides the effect of self-lubrication of a contact pair during operation, which causes a reduction in a friction coefficient and a wear rate compared to composite material without solid oil. Structural studies showed uniform distribution of solid oil in the entire volume of the composite, which provides an increase in tribotechnical characteristics due to formation of protective anti-gripping friction films at operation of a part of a complex shape under self-lubricating conditions.

The analysis of functional properties makes possible to recommend antifriction composite made on the basis of industrial grinding waste of AM4.5Kd aluminum alloy with impurities of solid lubricant ‒ МоS2 molybdenum disulfide for parts of complex compound joints, which operate at increased discrete sliding speeds and loads without lubrication with liquid oil in the air atmosphere.

Tribotechnical tests showed that the new composite wear-resistant material obtained by the developed manufacturing technology gives possibility to force maximum permissible loading modes and sliding operation rates with the consistently high antifriction properties of new composite friction parts of post-printing machines

Keywords


grinding waste; aluminum alloy; solid oil; structural studies; antifriction properties; post-printing machine

References


Gordon, N. J. (2016). Essentials of Polygraph and Polygraph Testing. CRC Press, 304. doi: https://doi.org/10.1201/9781315438641

Kyrychok, P. O., Roik, T. A., Havrysh, A. P., Shevchuk, A. V., Vitsiuk, Yu. Yu. (2015). Novitni kompozytsiini materialy detalei tertia polihrafichnykh mashyn. Kyiv: NTUU KPI, 428.

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Du, Z., Tan, M. J., Guo, J. F., Bi, G., Wei, J. (2016). Fabrication of a new Al-Al 2 O 3 -CNTs composite using friction stir processing (FSP). Materials Science and Engineering: A, 667, 125–131. doi: https://doi.org/10.1016/j.msea.2016.04.094

Dixit, S., Kashyap, S., Kailas, S. V., Chattopadhyay, K. (2018). Manufacturing of high strength aluminium composites reinforced with nano tungsten particles for electrical application and investigation on in-situ reaction during processing. Journal of Alloys and Compounds, 767, 1072–1082. doi: https://doi.org/10.1016/j.jallcom.2018.07.110

Kostornov, A. G., Fushchich, O. I. (2007). Sintered antifriction materials. Powder Metallurgy and Metal Ceramics, 46 (9-10), 503–512. doi: https://doi.org/10.1007/s11106-007-0078-5

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Roik, T. A., Havrish, A. P., Kholiavko, V. V., Havrysh, O. A., Prokhorenko, O. M. (2008). Pat. No. 34407 UA. Kompozytsinyi pidshypnykovyi material na osnovi aliuminiu. MPK (2006) C22C 21/02. No. u200803173; declareted: 12.03.2008; published: 11.08.2008, Bul. No. 15.

Jamroziak, K., Roik, T., Gavrish, O., Vitsiuk, I., Lesiuk, G., Correia, J. A. F. O., De Jesus, A. (2018). Improved manufacturing performance of a new antifriction composite parts based on copper. Engineering Failure Analysis, 91, 225–233. doi: https://doi.org/10.1016/j.engfailanal.2018.04.034

Konopka, K., Roik, T. A., Gavrish, A. P., Vitsuk, Y. Y., Mazan, T. (2012). Effect of CaF2 surface layers on the friction behavior of copper-based composite. Powder Metallurgy and Metal Ceramics, 51(5-6), 363–367. doi: https://doi.org/10.1007/s11106-012-9441-2

Roik, T. A., Gavrish, A. P., Kirichok, P. A., Vitsyuk, Y. Y. (2015). Effect of Secondary Structures on the Functional Properties of High-Speed Sintered Bearings for Printing Machines. Powder Metallurgy and Metal Ceramics, 54 (1-2), 119–127. doi: https://doi.org/10.1007/s11106-015-9688-5

Roik, T. A., Gavrysh, O. A., Vitsiuk, I. I., Khmiliarchuk, O. I. (2018). New Copper-Based Composites for Heavy-Loaded Friction Units. Powder Metallurgy and Metal Ceramics, 56 (9-10), 516–522. doi: https://doi.org/10.1007/s11106-018-9924-x

Wejrzanowski, T. (2005). Computer program Micrometer. Material Science, 23, 28–34.

Huliaev, A. P. (1986). Metallovedenye. Moscow: Metallurhyia, 544.

Kaloshkin, S. D., Tcherdyntsev, V. V., Laptev, A. I., Stepashkin, A. A., Afonina, E. A., Pomadchik, A. L., Bugakov, V. I. (2004). Structure and mechanical properties of mechanically alloyed Al/Al-Cu-Fe composites. Journal of Materials Science, 39 (16/17), 5399–5402. doi: https://doi.org/10.1023/b:jmsc.0000039253.28721.3f

Venkata Siva, S. B., Sreenivasa Rao, G., Sahoo, K. L. (2013). Tribological Studies of Al-based Composite. Developed from a Waste Material. 3-rd International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2013). Singapore, 10.

Zhang, J. Z. (2012). Research of Composite Material Properties Based on Waste Glass and Scrap Aluminum. Advanced Materials Research, 468-471, 2868–2871. doi: https://doi.org/10.4028/www.scientific.net/amr.468-471.2868

Kumar, S., Mathieux, F., Onwubolu, G., Chandra, V. (2007). A novel powder metallurgy-based method for the recycling of aluminum adapted to a small island developing state in the Pacific. International Journal of Environmentally Conscious Design & Manufacturing, 13 (3 (4)), 1–22.


GOST Style Citations


Gordon N. J. Essentials of Polygraph and Polygraph Testing. CRC Press, 2016. 304 р. doi: https://doi.org/10.1201/9781315438641 

Novitni kompozytsiini materialy detalei tertia polihrafichnykh mashyn / Kyrychok P. O., Roik T. A., Havrysh A. P., Shevchuk A. V., Vitsiuk Yu. Yu. Kyiv: NTUU KPI, 2015. 428 p.

Sviridenok A. I., Myshkin N. K., Kovaleva I. N. Latest developments in tribology in the journal Friction and Wear // Journal of Friction and Wear. 2015. Vol. 36, Issue 6. P. 449–453. doi: https://doi.org/10.3103/s106836661506015x 

Material properties of graphene/aluminum metal matrix composites fabricated by friction stir processing / Jeon C.-H., Jeong Y.-H., Seo J.-J., Tien H. N., Hong S.-T., Yum Y.-J. et. al. // International Journal of Precision Engineering and Manufacturing. 2014. Vol. 15, Issue 6. P. 1235–1239. doi: https://doi.org/10.1007/s12541-014-0462-2 

Fabrication of a new Al-Al 2 O 3 -CNTs composite using friction stir processing (FSP) / Du Z., Tan M. J., Guo J. F., Bi G., Wei J. // Materials Science and Engineering: A. 2016. Vol. 667. P. 125–131. doi: https://doi.org/10.1016/j.msea.2016.04.094 

Manufacturing of high strength aluminium composites reinforced with nano tungsten particles for electrical application and investigation on in-situ reaction during processing / Dixit S., Kashyap S., Kailas S. V., Chattopadhyay K. // Journal of Alloys and Compounds. 2018. Vol. 767. P. 1072–1082. doi: https://doi.org/10.1016/j.jallcom.2018.07.110 

Kostornov A. G., Fushchich O. I. Sintered antifriction materials // Powder Metallurgy and Metal Ceramics. 2007. Vol. 46, Issue 9-10. P. 503–512. doi: https://doi.org/10.1007/s11106-007-0078-5 

Bocian M., Jamroziak K., Kulisiewicz M. An identification of nonlinear dissipative properties of constructional materials at dynamical impact loads conditions // Meccanica. 2014. Vol. 49, Issue 8. P. 1955–1965. doi: https://doi.org/10.1007/s11012-014-9931-z 

Shevchuk Y. F., Roik T. A., Varchenko V. T. Antifriction composite materials for friction joints of centrifugal equipment // Powder Metallurgy and Metal Ceramics. 2007. Vol. 46, Issue 7-8. P. 404–407. doi: https://doi.org/10.1007/s11106-007-0063-z 

Pickens J. W. Assuring the Benefits of Aluminum Recycling: Engineering Economical Environmental Solutions to the Issues of Black Dross & Saltcake // Recycling of Metals and Engineercd Materials. 2013. P. 1195–1207. doi: https://doi.org/10.1002/9781118788073.ch105 

Process Control in Aluminum Foam Production Using Real-Time X-ray Radioscopy / Stanzick H., Wichmann M., Weise J., Helfen L., Baumbach T., Banhart J. // Advanced Engineering Materials. 2002. Vol. 4, Issue 10. P. 814–823. doi: https://doi.org/10.1002/1527-2648(20021014)4:10<814::aid-adem814>3.0.co;2-5 

Banhart J. Aluminium foams for lighter vehicles // International Journal of Vehicle Design. 2005. Vol. 37, Issue 2/3. P. 114. doi: https://doi.org/10.1504/ijvd.2005.006640 

Muchová L., Eder P. End-of-waste Criteria for Aluminium and Aluminium Alloy Scrap // Technical Proposals. 2010. 69 p.

Kompozytsinyi pidshypnykovyi material na osnovi aliuminiu: Pat. No. 34407 UA. MPK (2006) C22C 21/02 / Roik T. A., Havrish A. P., Kholiavko V. V., Havrysh O. A., Prokhorenko O. M. No. u200803173; declareted: 12.03.2008; published: 11.08.2008, Bul. No. 15.

Improved manufacturing performance of a new antifriction composite parts based on copper / Jamroziak K., Roik T., Gavrish O., Vitsiuk I., Lesiuk G., Correia J. A. F. O., De Jesus A. // Engineering Failure Analysis. 2018. Vol. 91. P. 225–233. doi: https://doi.org/10.1016/j.engfailanal.2018.04.034 

Effect of CaF2 surface layers on the friction behavior of copper-based composite / Konopka K., Roik T. A., Gavrish A. P., Vitsuk Y. Y., Mazan T. // Powder Metallurgy and Metal Ceramics. 2012. Vol. 51, Issue 5-6. P. 363–367. doi: https://doi.org/10.1007/s11106-012-9441-2 

Effect of Secondary Structures on the Functional Properties of High-Speed Sintered Bearings for Printing Machines / Roik T. A., Gavrish A. P., Kirichok P. A., Vitsyuk Y. Y. // Powder Metallurgy and Metal Ceramics. 2015. Vol. 54, Issue 1-2. P. 119–127. doi: https://doi.org/10.1007/s11106-015-9688-5 

New Copper-Based Composites for Heavy-Loaded Friction Units / Roik T. A., Gavrysh O. A., Vitsiuk I. I., Khmiliarchuk O. I. // Powder Metallurgy and Metal Ceramics. 2018. Vol. 56, Issue 9-10. P. 516–522. doi: https://doi.org/10.1007/s11106-018-9924-x 

Wejrzanowski T. Computer program Micrometer // Material Science. 2005. Issue 23. P. 28–34.

Huliaev A. P. Metallovedenye. Moscow: Metallurhyia, 1986. 544 p.

Structure and mechanical properties of mechanically alloyed Al/Al-Cu-Fe composites / Kaloshkin S. D., Tcherdyntsev V. V., Laptev A. I., Stepashkin A. A., Afonina E. A., Pomadchik A. L., Bugakov V. I. // Journal of Materials Science. 2004. Vol. 39, Issue 16/17. P. 5399–5402. doi: https://doi.org/10.1023/b:jmsc.0000039253.28721.3f 

Tribological Studies of Al-based Composite / Venkata Siva S. B., Sreenivasa Rao G., Sahoo K. L. // Developed from a Waste Material. 3-rd International Conference on Mechanical, Automotive and Materials Engineering (ICMAME'2013). Singapore, 2013. 10 p.

Zhang J. Z. Research of Composite Material Properties Based on Waste Glass and Scrap Aluminum // Advanced Materials Research. 2012. Vol. 468-471. P. 2868–2871. doi: https://doi.org/10.4028/www.scientific.net/amr.468-471.2868 

A novel powder metallurgy-based method for the recycling of aluminum adapted to a small island developing state in the Pacific / Kumar S., Mathieux F., Onwubolu G., Chandra V. // International Journal of Environmentally Conscious Design & Manufacturing. 2007. Vol. 13, Issue 3 (4). P. 1–22.







Copyright (c) 2018 Tetiana Roik, Oleg Gavrish, Volodimir Oliynik, Iuliia Vitsiuk

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ISSN (print) 1729-3774, ISSN (on-line) 1729-4061