1.
Wear
Definition
Wear is the gradual removal or deformation of material at solid surfaces due to mechanical
action.
Types of Wear:
1. Adhesive Wear – Due to local bonding between contacting surfaces.
2. Abrasive Wear – Hard particles or rough surfaces cause material removal.
3. Fatigue Wear – Repeated loading causes surface cracks and material loss.
4. Corrosive Wear – Wear combined with chemical reactions.
5. Erosive Wear – Material removal due to impact of fluid or particles.
6. Fretting Wear – Small oscillatory motion at contact surfaces causes wear.
Causes of Wear:
* Friction between moving parts
* Presence of abrasive particles
* Improper lubrication
* Excessive loads or vibrations
* Chemical attacks
Effects of Wear:
* Reduced efficiency
* Increased maintenance cost
* Component failure
* Heat generation and noise
* Surface roughness
Wear Reduction Methods:
* Use of proper lubricants
* Surface hardening
* Use of wear-resistant materials (e.g., alloys)
* Heat treatments
* Improved design and maintenance
2. Lubricants
Types and Applications:
1. Solid Lubricants– Graphite, MoS₂; used in extreme temperature or vacuum.
2. Semi-solid Lubricants – Greases; used in moderate-speed machinery.
3. Liquid Lubricants– Mineral and synthetic oils; used in engines, machines.
4. Gas Lubricants – Air or gas used in high-speed, low-load conditions.
3. Lubrication Methods
Purpose: To reduce friction and wear between moving surfaces.
i. Screw Down Grease Cup:
Sketch: A cup with screw plunger that pushes grease into bearing.
Working: Turning screw feeds grease slowly.
Applications: Low-speed bearings, manual greasing.
ii. Pressure Grease Gun:
Sketch: Hand-held gun with trigger and nozzle.
Working: Manual pressure injects grease into fittings.
Applications: Automotive, industrial machines.
iii. Splash Lubrication:
Sketch:Gear or crankshaft splashes oil in enclosed casing.
Working: Moving parts splash oil onto other parts.
Applications: Small engines, gearboxes.
iv. Gravity Lubrication:
Sketch:Reservoir above parts; oil flows by gravity.
Working:Gravity feeds oil drop-by-drop.
Applications:Overhead oilers in machines.
v. Wick Feed Lubrication:
Sketch: Wick draws oil from reservoir to surface.
Working: Capillary action moves oil.
Applications: Clocks, small instruments.
vi. Side Feed Lubrication:
Sketch: Oil supplied through side holes and channels.
Working: Oil flows through holes by pressure or gravity.
Applications: High-speed tools.
vii. Ring Lubrication:
Sketch: A ring dipped in oil rotates with shaft.
Working: Ring carries oil from reservoir to shaft.
Applications: Electric motors, turbines.
4. Corrosion
Corrosion is the chemical or electrochemical reaction between material (usually metal) and
environment, causing material degradation.
Principle:
Involves anodic (oxidation) and cathodic (reduction) reactions.
Factors Affecting Corrosion:
* Metal type and composition
* Environment (humidity, temperature, pH)
* Surface finish
* Presence of salts or pollutants
* Oxygen availability
Types of Corrosion:
1. Uniform Corrosion– Even metal loss.
2. Galvanic Corrosion– Between dissimilar metals in contact.
3. Pitting Corrosion– Localized small holes or pits.
4. Crevice Corrosion – In shielded areas or gaps.
5. Intergranular Corrosion– Along grain boundaries.
6. Erosion Corrosion – Accelerated by fluid motion.
7. Stress Corrosion Cracking (SCC) – Due to tensile stress and corrosive environment.
5. Corrosion Prevention Methods:
1. Material Selection:
* Use corrosion-resistant alloys (e.g., stainless steel)
2. Protective Coatings:
Paint, enamel, plastic coatings
Metallic coatings like galvanizing (Zn), anodizing
3. Cathodic Protection:
Sacrificial Anode Method: Use more reactive metal (e.g., Zn, Mg)
Impressed Current Method: External power source supplies electrons
4. Inhibitors:
Chemicals added to fluid environments to slow corrosion.
5. Design Improvements:
* Avoid crevices
* Ensure drainage
* Use compatible metals