Surface Failures & Types of Waer 1

SURFACE FAILURES &

DIFFERENT TYPES OF WEAR
 SURFACE GEOMETRY
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 Most solid surfaces that are subject to wear in machinery

will be either machined or ground, though some will be as-
cast or as-forged. In any case, the surface will have some
degree of roughness that is concomitant with its finishing
process. Its degree of roughness or smoothness will have an
effect on both the type and degree of wear that it will
experience.
 Even an apparently smooth surface will have microscopic
irregularities. These can be measured by several methods.
 The microscopic "mountain peaks" on the surfaces are
called asperities.
Surface Failures & Types of Waer
 MATING SURFACE
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 When two surfaces are pressed together under load, their

apparent area of contact Aa is easily calculated from
geometry, but their real area of contact Ar is affected by the
asperities present on their surfaces and is more difficult to
accurately determine.

Surface Failures & Types of Waer

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 As the mating force is increased, the asperity tips will

yield and spread until their combined area is sufficient to
reduce the average stress to a sustainable level.
 The real area of contact can then be estimated from:

where F is the force applied normal to the surface.

Surface Failures & Types of Waer

 WEAR
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 Wear is the sideways displacement of material from

its “derivative” and original position on a solid
surface performed by the mechanical action from
another surface.
 Wear is the undesirable removal of solids from a
sliding or rolling component.
 Wear is generally proportional to the applied load
and the amount of sliding.

Surface Failures & Types of Waer

 Adhesive Wear
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Adhesive Wear- the removal of material due to adhesion

between surfaces.
1. Mild adhesion- is the removal of surface films, such as
oxides, at a low rate.
2. Severe adhesion- the removal of metal due to tearing,
breaking, and melting of metallic junctions.
This leads to scuffing or galling of the surfaces and even
seizure.

Adhesive wear on a shaft

Surface Failures & Types of Waer
 Adhesive Wear- Prevention
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Mechanical
1. Reduce load, speed and temperature.
2. Improve oil cooling.
3. Use compatible metals.
4. Apply surface coatings such as phosphating.
LUBRICANT
5. Use more viscous oil to separate surfaces
6. Use “extreme pressure” additives such as sulfurhosphorous
or borate compounds.

Surface Failures & Types of Waer

 Abrasive Wear
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 Abrasive Wear- the cutting of furrows on a surface by hard

particles.
eg: sand particles between contact surfaces, or hard asperities
on an opposing surface.
 Abrasive wear occurs when a hard rough surface slides across

a softer surface.

Surface Failures & Types of Waer

 Abrasive Wear- Prevention
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Mechanical
1. Remove abrasive by improved air and oil filtering, clean
oil handling particles, improved seals, flushing and
frequent oil changes.
2. Minimize shot peening, beading, or sand blasting of
surfaces because abrasives cannot be completely removed.
3. Increase hardness of metal surfaces.
Lubricant
4. Use oil free of abrasive particles.
5. Use more viscous oil.
Surface Failures & Types of Waer
 Corrosive Wear
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 Corrosive Wear- the removal of corrosion products from a

surface by motion, such as the rubbing off rust.
 Corrosion wear adds to the chemically corrosive
environment a mechanical disruption of the surface layer due
to a sliding or rolling contact of two bodies.
 This surface contact can act to break up the oxide (or other)
film and expose new substrate to the reactive elements, thus
increasing the rate of corrosion.

Surface Failures & Types of Waer

 Corrosive Wear- Prevention
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Mechanical
 Use more corrosion resistant metal.
 Reduce operating temperature.
 Eliminate corrosive material.
Lubricant
 Remove corrosive material such as too chemically active
additive and contaminates.
 Use improved corrosion inhibitor.
 Use fresh oil.

Surface Failures & Types of Waer

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Thank You

Surface Failures & Types of Waer