Tampere Wear Center & Research equipment 2014

Tampere Wear Center
&
Research Equipment
Kati Valtonen
Project Manager
Tampere University of Technology
Department of Materials Science
Tampere Wear Center

Tampere University of
Technology (TUT)
– At the Leading Edge
• Established in 1965
• Started operating in the form of a foundation in 2010
• 9,900 students (2013)
• Collaborates with 230 universities around the world
• Quality assurance system audited by The Finnish Higher
Education Evaluation Council in 2014

Internationally high-level know-how on all materials based on
strong interdisciplinary basic research

• The only higher education unit in Finland covering all material
groups
– Personnel about 160, 11 professors, Head of the Department Prof. Erkki
Levänen
– Over 900 M.Sc. (Eng.), 80 Lic.Tech., and 60 Ph.D. thesis and more than
6000 publications since 1969
– International Degree Programme in Materials Science
• High-level basic research of the structure, properties, processing,
and use of materials
– Researcher with knowledge of and expertise in all groups of materials
– Versatile and up-to-date research and testing equipment
• Strong collaboration with industry and academic units
– Research funding comes mainly from industry, SHOKs, Tekes, Academy
of Finland, and the EU
• Networks internationally and participates in international research
projects
– scientific collaboration and research exchange

Tampere Wear Center - TWC
• Concentrates on both scientific and practical
aspects of wear and tribology
• Strengthens research in the field of wear and
tribology of materials
• Networks internationally
• Develops wear-related problem-solving
services for industry
• Versatile and up-to-date research and testing
equipment
• Researchers with knowledge and expertise
on all groups of materials
• Numerical contact modeling and experimental
verification of the models
• Special expertise areas heavy abrasion,
impact wear, fretting and tribology of machine
elements, such as gears, bearings, brakes,
seals, and frictional joints

TWC – Wear Research
• TWC has excellent infrastructure for wear research, as well as highly
qualified scientists and research engineers for the needs of both long-
term scientific research and product development for the industry
• Wear research is conducted in close collaboration with several
internationally recognized partners, such as the National Research
Council of Canada (NRC), the Austrian Excellence Center for Tribology
(AC2T), VITO, TEKNIKER, the University of Sheffield, the University of
Southampton, the University of Manchester, Luleå University of
Technology, and Tallinn University of Technology. Of these, NRC, AC2T
and the University of Southampton have also been recently targets of
research exchange.
• One example of TWC’s international activities is the recently founded
Nordic Hard Rock Tribology Network, RockTrib, embracing several key
research institutes in the field of hard rock tribology in Nordic countries,
including Norwegian University of Science and Technology (NTNU),
SINTEF, Luleå University of Technology, Uppsala University, Dalarna
University, and VTT.

TWC projects 1/2
• FIMECC BSA: Design beyond present codes
– Optimization, prediction and design guidelines for improved wear life of
novel steels and metallic multimaterials
– Surface fatigue and extreme load carrying capacity of gears
• FIMECC HYBRIDS: Multifunctional thick coatings and composites
– Metallic coatings for process environments
– Multifunctional MMC coatings
– Low-friction coatings
– Abrasive coatings
– Damage-tolerant ductile ceramic coatings
– Thick ceramic coatings / bulk linings
– Corrosion resistant coatings/structures against acidic liquid environments
• FIMECC HYBRIDS: Polymeric multifunctional sliding materials
– Oil free sliding, rolling, and flow contacts
– Lubricated sliding bearings and fixed connected surfaces
• FIMECC BSA & HYBRIDS: Fundamentals and modelling

TWC projects 2/2
• FIMECC DEMAPP: Wear resistant materials and solutions
– Characterization and development of the microstructure, properties and
performance of wear resistant materials for selected environments
– Modeling and simulation of wear processes
– Novel coating processes for wear protection
– Friction and wear of polymers
• FIMECC DEMAPP: Friction and energy
– High friction low wear contacts
– Low friction in process environment
• FIMECC LIGHT: Low density materials
– Slurry-erosion testing of GFRP laminates
– Dynamically loaded wear resistant steel-
polymer hybrids
• Research services for industry and other
units

Research equipment
• Wear testing: Pin-on-disk/Ball-on-disk, Crushing
pin-on-disk, Uniaxial crusher, Dual pivoted jaw
crusher, Impeller-tumbler, Erosion tester, High-
speed slurry-pot type erosion tester, Cavitation
erosion tester, High velocity particle impactor,
Ball-on-block, Hammer mill, High-speed sliding
test rig, Single disc refiner, Pin-on-plate,
Biomaterial crusher, Block-on-ring, Rubber wheel
abrasion testers, etc.
• Tribology and machine elements test rigs: Test
rigs for journal, thrust, and rolling bearings, FZG,
Twin-disc test rig, Fretting wear and fatigue test
rigs, Vibration Testing, etc.
• Electron microscopes (UHR FEG-SEM, TEM)
• Hopkinson Split Bar
• Digital image correlation system
• Mechanical testing
• Thermal spraying
• Other equipment

CETR UMT-2 Pin/Ball-on-disk
Commercial Pin-on-disk / Ball-on-disk equipment;
fulfills ASTM G99 –95a standard
Elevated-Temperature Chamber:
• Temperature: -20-350°C
• Revolve disk speed: 0.1 - 1000 rpm
• Max. disk size: 70 mm
• Standard specimens:
•Pins: Diameter of 6.35 and 10 mm
•Balls: Diameter of 6.35 and 9.5 mm
• Humidity/Gases Chamber (no controls)
• Possibility to use lubricants
• Humidity control: 5-95%RH
High-Temperature Chamber:
• Temperature up to 1000°C
• Revolve disk speed: 0.1 - 1000 rpm
• Max. disc size: 50 mm
• Standard specimens:
•Pins: Diameter of 6.35 and 10 mm
•Balls: Diameter of 6.35 and 9.5 mm

Crushing Pin-on-disk
• Pin is repeatedly pressed against
the gravel bed and the disk with a
pneumatic cylinder (200-500N)
• Pin does not come into direct
contact with the disk at any time ®
wear of the components due to
abrasive ploughing and cutting on
the pin and disk surfaces
• During the test, the abrasive size
decreases at different rates,
depending on the pin-disk
combination.
• Simulates cone or jaw crusher
Disk:
* Diameter of 160 mm
* Thickness of 2-155 mm
* Rotating velocity control
Specimen:
* Diameter of 36 mm
* Height of 35 mm
* Flat area 1000 mm²

Uniaxial Crusher
• The equipment crushes the abrasive uniaxially
between two specimens with a high pressure
• Controlled amount of the abrasive
• Simulates a mineral crusher
• Specimen: area of 1000mm², height of 35 mm and
diameter of 36 mm
• Impacts with the hydraulic cylinder:
• 6 bar (max) 86 kN
• 5 bar 69 kN
• 4 bar 53 kN
• 3 bar 39 kN
• 2 bar 23 kN

Dual pivoted jaw crusher
• A novel reduced-size laboratory scale
jaw crusher for studying the
mechanisms of abrasive wear during
mineral crushing
– Replaces/complements the standardized
test ASTM G 81-83
• Key design features:
– control of jaw movement without changing
the test geometry, enabling accurate control
of the compression-sliding ratio
– versatile instrumentation for monitoring the
wear processes, including piezoelectric force
sensors, high speed video systems, etc.
• Specimen
– small jaw plate size 75*25*10 mm
concentrates the abrasion to a small area
– abrasive particle size 6-14 mm

Impeller-tumbler impact-
abrasive wear tester
• During the test, an impeller rotates inside a rotating tumbler filled with gravel.
Three samples are attached to the impeller. As the impeller and the tumbler
rotate, gravel moves inside the tumbler and impacts on the specimens.
• Impeller rotating speed up to 700 rpm
• Tumbler rotating speed up to 120 rpm
• Specimen: 75*25*10 mm
• Variables: gravel size distribution, type, and amount

High-speed slurry-pot type
erosion tester
• Testing of wear resistant materials for
mining and dredging pumps
• Testing of mineral abrasivity in slurry
or in dry conditions
• Specimens:
– Profile: round or square
– Thickness 18.5 mm / 15 mm
– Length 65.5 mm from shaft
• Slurry:
– Up to 10 l of water
– Abrasive size 0-10 mm
– Selectable amount of abrasive
• Shaft:
– Diameter 60 mm
– Rotation speed up to 2000 rpm
– Specimen tip speed up to 20 m/s

Erosion tester
Wear testing of materials and coatings at room
temperature with centrifugal accelerator
• Impact angle: 15°, 30°, 45°, 60°, or 90°
• Impact velocity: 0-80 m/s
• Abrasive typically quartz
• Abrasive size: up to 1 mm
• Sample size: 20*15 mm, thickness 5 mm
• Samples quantity: up to 15 samples

Test Method for Cavitation Erosion
Using Vibratory Apparatus
• Standard test ASTM G32-10
• Vibra-Cell VCX-500 ultrasonic
processor
– Allows process control and
monitoring from 1°C to 100°C
Replacable Ti-6Al-4V tip
for cavitation testing.
Test parameters
Frequency 20 kHz
Amplitude 50 μm
Distance to sample 0.6±0.1 mm
Water temperature 25±1 °C
Tip diameter 13 mm

High Velocity Particle Impactor
• Barrel diameter: 9 mm
• Shooting distance: 0.5...1.5 m
• Pressure system: pressurized air up to
16 bar
• Video recording: high speed camera
NAC MEMRECAM up to 80 000 fps
• Light system: up to 4 500 W
Trap wall
Target
assembly
Speed
measurement
device
Smooth bore Pressure
control
Pressurized
air tank
Specimen
• Projectiles: e.g. metallic or ceramic ball
bearing balls, cylinders, bullets, rocks, …
• Projectile’s speed: 30…200 m/s
• Target’s angular position: 0°...90°
• Developed for the model verification

Ball-On-Block Impact Wear
Testing Device
• Ball-on-block is a high-energy impact wear testing
device that produces repeatedly high-energy
impacts to the surface of the specimen
• Impacts are created by shooting a ball to the
specimen using a pneumatic cylinder
• Simulates wear on a SAG-mill
• Ball:
– mass 8 kg and diameter 125 mm
– Impact velocity 8-12 m/s (Ek = 256 J – 576 J)
– material for example tempering steel
• Specimen:
– size 200x200x75 mm or 200x200x50 mm
– various materials tested such as steels, rubbers,
metal matrix composites, hard metals

Hammer-mill Type Impact Wear
Testing Device
• Two rotating hammers
• The abrasive is fed between the hammer and
the specimen from a container through a
feeder tube
• Hammers:
– Speed: 5,1-9,0 m/s
– Impact energy: 21,9-66,9
– Typical speed 7 m/s and impact energy 50 J
• Specimen:
– 80mm x 80mm – 250mm x 250mm
– Thickness 15-45mm

High-speed sliding test rig
• Simulates the high-speed sliding
conditions in modern paper-
making processes
• Up to four samples can be tested
at once
• Slurry composition adjustable
• Automated slurry level
adjustment and several self-
monitoring features ® test runs
can be set up to run for days
• Wear rates are lower than those
provided by the ASTM G 65
standard test

Biomaterial crusher
• Biomaterial crusher is used to test the wear of cutting blades. The equipment will
be used in field tests.
• Biomaterial crusher is fed from the top with belt conveyor
• Feeding to cutting blades with hydraulic press
• The 14 blades can be changed one by one
• Crusher is controlled with programmable logic
• The capasity of the crusher is about one cubic meter of biomaterial in one hour

Surface fatigue wear
• Attached to MTS
• Holder moves after
every step
• Intender ball or spike

Other wear equipment
Dry Sand Rubber Wheel
Abrasion Testing Device
Slurry Abrasion Testing Device
Block-on-Ring

Tribology and
machine elements test rigs
• Journal bearing test rig
• Thrust bearing test rig
• Gears and lubricants (FZG) test device
• Test environment for power transmission components
like gearbox, 100 kW
• Rolling bearing test rig
• High pressure twin-disc test rig
• Fretting wear and fatigue test rig – sphere-on-plane
contact
• Fretting wear and fatigue test rig – complete contact
• Advanced vibration and noise instruments
• Tribology equipments
– Optical profiler
– Viskometer
– Microscopes
– Ferrography
– Pin-on-disc test device

Journal bearing test rig
Contacts:
Juha Miettinen, juha.s.miettinen@tut.fi
Arto Lehtovaara, arto.lehtovaara@tut.fi
Test bearings and acting forces
Test targets – evaluation of bearing performance
- friction, power loss
- failure modes, life
- lubricants, lubrication condition
- temperatures, fluid film pressures
- bearing materials and configurations
Specifications:
- sliding speed 0.05 … 16 m/s
- projected pressure 0 … 15 MPa
- oil temperature, pressure and flow controls
- shaft misalignment control
- no support bearings

Thrust bearing test rig
Test targets: evaluation of thrust bearing
performance
- friction and power loss
- load capasity
- bearing materials and configurations
- failure modes
Specifications:
- rotating speed 0 – 2000 rpm
- external lubrication unit with oil filtering and
temperature, flow and pressure control
Contacts:

Test targets: testing gear contact and
lubrication properties
- durability testing
- failure mechanisms, pitting, scuffing
- vibration and noise diagnostics
Specifications:
- closed loop type rig
- loading torque 0 ... 1000 Nm
- rotating speed 0 ... 3000 rpm
Contacts:
FZG Gear test rig

Test targets: performance and durability
tests of different power transmission
components
- lubrication condition
- failure mechanisms
- prototype testing
- vibration and noise diagnostics
Specifications:
- generator brake type rig
- isolated concrete foundation
- machine rail floor allows installation changes
- noise isolated test room
- max. power transmission 100 kW
- rotating speed 0 ... 2400 rpm
Contacts:
Power transmission test rig
Versatile measurement possibilities

Roller bearing test rig
Test targets: evaluation of roller bearing
performance
- lubricants, lubrication condition
Specifications
- bearing outer diameter 90 mm
- normal and axial loading
- oil (bath) temperature control or
Contacts:

Test targets: gear and rolling/sliding contact
testing
- contact friction
- fatigue durability
- lubrication condition
Specifications:
- adjustable elliptical rolling/sliding contact
- contact pressure 0 ... 2.5 GPa
- static and dynamic loading
- disc grinding transversal
- automated operation and sequence
- advanced instrumentation
- contact resistance measurement
Contacts:
Twin-Disc test rig

Test targets: fretting in complete contacts
(i.e. ’sharp-ended’ flat-on-flat type contacts)
- fretting and plain fatigue S-N curves
- fretting wear
Specifications:
- large contact 200 mm2
- nominal contact pressure 0 … 200 MPa
- fully reversing or fluctuating bending loading
- frequency 0 … 50 Hz
- automated operation (unoccupied testing)
Contacts:
Janne Juoksukangas, janne.juoksukangas@tut.fi
Complete contact fretting test rig

Sphere on plane fretting test rig
Test targets: Fretting experimentation
with Hertzian point contact
- fretting fatigue
- fretting wear
- friction
- partial and gross sliding conditions.
Specifications:
Large contact radius: 0.2 … 0.5 m
Loading frequency: 40 Hz
Normal force: 500…3300 N
Displacement amplitude: 5…60 µm
Contacts:
Jouko Hintikka, jouko.hintikka@tut.fi

Contacts:
Vibration Testing
• Vibration equipment for monitoring, diagnostics and testing
• Industrial and laboratory applications
• LMS system for machinery vibration and modal testing
• IMC data acquisition systems
• B&K and LDS shakers
• Versatile sensors for different purposes
• Strain gage equipment, wireless
• Acoustic emission vibration and sound equipment
• Versatile analysis software

Scanning Electron Microscope
Zeiss ULTRAplus
• Ultra high resolution field emission SEM
• Detectors: inlens SE, EsB, AsB, Everhart
Thornley SE, and STEM
• Resolution 1.0 nm@15 kV and 1.7 nm@1 kV
• Accelerating voltage 100 V - 30 kV; beam
current up to 40 nA
• Charge compensator for non-conductive
samples
• INCAx-act Energy Dispersive X-ray
Spectrometer (EDS)
• HKL Premium-F Channel EBSD system with
ultrafast Nordlys F400 detector
• SIS Scandium image analysis and processing
software
• K1050XT RF Turbo plasma asher

Analytical Transmission
Electron Microscope Jeol
JEM 2010
Analytical Transmission Electon Microscope (TEM)
is equipped with an energy dispersive X-ray
spectrometer (EDS) and digital camera system. This
microscope is used primarly for studing the structure
and chemistry of materials at high spatial resolution.
• LaB6 electron source
• Point resolution 0.23 nm
• ± 30° of eucentric specimen tilt
• convergent beam electron diffraction (CBED)
and selected area diffraction (SAED)
NORAN VANTAGE Energy Dispersive X-ray
spectrometer (EDS) with Si(Li) detector
GATAN ORIUS SC600 digital camera system
• 7 megapixel CCD sensor
• Peltier cooling

Characterization of wear
• Optical and stereo microscopes
• Retsch AS 200 analytical sieve shaker
• Precica XB4400 ja XT1220 weighers
• Veeco WYKO NT1100 optical profilometer

Hopkinson Split Bar, HSB
• Based on the propagation of elastic waves in
slender bars
• Type of loading: Compression, tension, or
shear.
• Duration of the loading pulse [µs]: 50 - 600
• Strain rate range [s-1]: 2·102 - 104
• Loading range [kN]: 0 - 250
• Temperature range [°C]: -190 - 1000

High Speed Video Systems
• Cordin 535-16
• High Resolution Rotating Mirror CCD
Framing Camera System.
• Number of Frames: 16
• Maximum framing Rate: 1 million
• Minimum Interframe time: 1.0 us
• Minimum Exposure Time: 800 ns
• Resolution: 1000 x 1000 pixels
• Pixel size: 7.4 x 7.4 mm
• Dynamic Range: 10 bit
Memrecam fx K5
• Provides ultra high light sensitivity, ultra
high speed and mega pixel resolution
• Megapixel Sensor
• Frame rates up to 168,000fps
• Ultra-High Light Sensitivity— ISO 5,000
Colour & 32,000 Monochrome
• 1280 x 1024 resolution

3D Digital Image Correlation Systems
Two independent LaVision StrainMaster 3D DIC systems that can be operated
independently.
Low rate system
• 2 cameras: Imager E-Lite 5MPix CCD cameras.
– 12bit images, 12 fps at full resolution
• Additional Zeiss Discovery v.8 stereo microscope with horizontal mounting
system
High rate system
• 2 Cameras: Photron SA-X2
– 12 bit images, 1MPix maximum resolution. 12.500 fps at max.res. Higher fps at reduced
resolution,e.g. 200kHz at 256*152.
– 16GB of internal memory, recording time around 0.7 to 10 seconds depending on the
resolution and fps
• A rigid mounting system for the cameras and lights and high speed trigger unit

Thermal spraying at TUT
• Plasma spraying (Plasmatechnic A3000)
• Arc spraying (Sulzer Metco 6RC)
• Wire flame spraying (Sulzer Metco 12E)
• Powder flame spraying (Sulzer Metco 6P-II and
Castolin DS 8000)
• Detonation spraying (Perun P D-gun)
• High velocity oxygen fuel (HVOF) spraying (Sulzer
Metco DJ Standard and DJ Hybrid)
• High velocity air fuel (HVAF) spraying (Uniquecoat
Technologies M3 Supersonic Spray Gun)
• Low-pressure cold spraying (Dymet 304K)
• High-pressure cold spraying (CGT Kinetiks 3000)
Spraying
method
Process
temperature
(°C)
Particle
velocity
(m/s)
Plasma 12000 200 - 400
Arc 4000 100
Flame 3000 40
Detonation 4000 900
HVOF 3000 800
Cold 25 - 800 550 - 1200FLAME PLASMA
HVOF
ARC

SETEC 14
SAMPE Europe Technical
Conference & Table Top
Exhibition
10.-11.9.2014 Vapriikki,
Tampere
Scientific conference for Smart and
functional textiles, Well-Being, Thermal
comfort in clothing, Design, Thermal
Manikins and Modelling
7.-9.9.2014 Tampere Hall, Tampere
www.tut.fi/mol
NORDTRIB 2016
14.-17.6.2016
Aulanko, Hämeenlinna,
Finland

Tampere University of Technology
Tampere Wear Center
www.tut.fi/mol
www.tut.fi/twc

Tampere Wear Center & Research equipment 2014

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