Bayer R.G. Mechanical Wear Fundamentals and Testing, Revised and Expanded
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sites (MMC). An example of such a wear map is shown in Fig. 3.89. In this type of
application, ambient temperature is also a factor and these types of curves were devel-
oped for a series of temperatures, which spanned the application range. A third form
of a wear map that is used to characterize solid particle erosion is the ternary map
shown in Fig. 3.90. This is a wear mechanism map in which four different modes of
wear are identified. The fractured dominated and plastic mechanisms are mechanisms
associated with the wear of the reinforcing particle, while the remaining two are wear
modes associated with the composite (171). This map shows the combined effect of
temperature, velocity, composition, and particle size on type of mechanism involved
(164,172).
A common example of a wear map is the PV diagrams (pressure–velocity graphs)
often used to describe the wear behavior of engineering plastics. In this case, the PV Limit
curve separates pressure and velocity combinations into two regions of wear behavior, one
that is generally considered to be acceptable for applications and the other that is not
(173).
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194. L Ives, A Ruff. Election microscopy study of erosion damage in copper. In: W Adler, ed. Ero-
sion: Prevention and Useful Applications. STP 664, ASTM, 1979, pp 5–35.
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
4
Wear Behavior and Phenomena
4.1. GENERAL BEHAVIOR
Some trends in wear behavior are shown in Figs. 4.1–4.7. Individually, these trends do
not necessarily represent general behavior, since they are based on published data from
specific wear tests and general ly involve a limited number of materials a nd conditions
(1–16). While limited, the data summarized in these figures illustrate the broad range of
behavior that can be encoun tered in different wear situations. Several of these figures con-
tain wear curves, that is, the graphical relationship between wear and usage (distance of
sliding, time, number of cycles, etc.). Others illustrate the depen dency of wear on various
factors, such as load, roughness, speed, hardness, etc., which are significant to the design
engineer. As can be seen by comparing the various graph s in these figures, a variety of
plotting techniques is used, including linear, log–log, and semi-log, to summarize the beha-
vior. The need to use such a variety of formats illustrates the variety of relationships and
sensitivities that are associated with wear. The general character of the curves is often
some form of nonlinear behavior. In several of these figures, a power relationship (x
n
)
between wear and the parameter is indicated; in others, transitions or max=min behavior
is seen. At the same time, linear relationships or regions of linear behavior can often be
found in these figures as well.
A frequently encountered behavior is the development of a period of stable wear
behavior after some initial wear has taken place (1,6,8–14,17–20). A period of stable wear
behavior is one in which there is a stabilization of wear mechanisms. Typically, in situa-
tions where the apparent contact area does not change with wear, this is also a period
of lower and constant wear rate, after a initial period of higher and changing wear rate.
This type of behavior is shown in Figs. 4.8 and 4.9. In such situations, the initial period
is usually referred to as break-in. Break-in behavior results from surface and near-surface
changes as a result of relative motion and wear and the emergence of different mecha-
nisms. This break-in effect is in addition to and different from the run-in e ffect associated
with conforming contacts. With nominally conforming contacts, there can be an apparent
break-in period when a linear wear measure is used, such as scar depth or width. In this
case, the depth wear rate decreases as true conformity is established by wear, even if there
is no other change occurring. However, other break-in type changes are also common with
run-in. An additional discussion of break-in behavior can be found in Sec. 4.4.
The morphology of the wear scar is generally different in the break-in and stable wear
periods. Stable wear behavior is generally characterized by stable morphology. Volume wear
rates are often constant in stable wear periods, as indicated previously. However, short-term
cyclic variations and slowly decreasing wear rates are also possible in these periods (4,21).
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
Figure 4.1 The effect of hardness on wear in several situations. ‘‘A’’, two-body abrasion of cast
irons and steels; ‘‘B’’, sliding against paper; ‘‘C’’, sliding contact; ‘‘D’’, rolling contact. (‘‘A’’ from
Ref. 9; ‘‘B’’ from Ref. 75.)
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.
This distinction between initial and long-term wear behavior is significant for
several reasons. One is that run-in and break-in are precursors to stable wear beha-
vior. For the designer or engineer, this means that suitable break-in may be required
to obtain the stable period of low wear rate needed for long life. If this break-in does
not occur, higher wear rates and unstable behavior might persist, resulting in reduced
life. It is also important in engineering because it is sometimes necessary to take into
account the magnitude of the wear associated with this initial period. It is also signi-
ficant in terms of its relationship to wear studies. To the investigator, this stable
period provides a convenient region for wear study. It is typically the type of region
Figure 4.2 The effect of roughness in sliding. ‘‘A’’, steel against steel; ‘‘B’’, plastic against stainless
steel. (‘‘A’’ from Ref. 10; ‘‘B’’ from Ref. 16.)
Copyright 2004 by Marcel Dekker, Inc. All Rights Reserved.