Tampere Wear Center activities and research equipment 2015

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

• Established in 1965
• Started operating in the form of a foundation in 2010
• 9,900 students (2013)
• Collaborates with 200 universities around the world
• Quality assurance system audited by The Finnish
Higher Education Evaluation Council in 2014
Tampere University of Technology (TUT)
– At the Leading Edge

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

4.6.2015 4
• Personnel, total 110 (Academic) 132 total
• Professors 6+2
• Researchers 86
• Funding, total 9.2 M€ ( 70 % from outside)
• 1000 (M.Sc. thesis) 2014: 60 M.Sc.
• 70 Doctors of Technology 2014: 5 Dr. Tech
• 6000 publications 2014: 90 peer-rev.
• 40 % of Finland’s materials experts
• Over 100 projects running
Tribology and
Machine Elements
Materials
Characterization
Metals Technology Plastics and
Elastomer
Technology
Surface Engineering
Fibre Materials
Science
Paper and
Packaging
Ceramic Materials
Veli-Tapani Kuokkala
Veli-Tapani Kuokkala
Erkki Levänen
Head of Department
Arto Lehtovaara
Jyrki Vuorinen
Pasi Peura
Petri Vuoristo
Jurkka KuusipaloMinnamari Vippola
TWC (Tampere Wear Center)
LAL (Laser Application Laboratory)
TSCF (Thermal Spray Center Finland)

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), Mines ParisTech, 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, Mines ParisTech, 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
– Materials in Mining Industry: Optimization, prediction and design guidelines for
improved wear life of novel steels and metallic multimaterials
– Energy and Life Cycle Efficiency: Surface fatigue and extreme load carrying capacity
of gears
• FIMECC BSA & HYBRIDS: Fundamentals and modelling
• 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 HYBRIDS: Multifunctional thin coatings

TWC projects 2/2
• Elasto-hydrodynamic contact performance
under ice loads - ArTEco
• Accelerated life cycle estimation
• Short crack and fretting fatigue damage in
mechanical engineering
• 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, 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 (FEG-SEM, FIB-SEM, TEM)
• Hopkinson Split Bar
• Digital image correlation system
• Mechanical testing
• Thermal spraying
• Other equipment at DMS

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

Dual pivoted jaw crusher
Compression
compression/sliding ratio 10:1
Sliding
compression/sliding ratio 1:8

Impeller-Tumbler Impact-Abrasive
Wear Tester
• Simulates wear in mineral handling applications, such as earth moving
machinery and impactor plants.
• During the test, an impeller with three samples (75*25*10 mm) rotates
inside a rotating tumbler filled with gravel.
‒ Impeller rotating speed up to 700 rpm,
tumbler rotating speed up to 120 rpm
‒ Variables: sample angle, gravel size
distribution, type, and amount
‒ One sample is the reference ® changes
in mineral composition controllable

High-speed slurry-pot type erosion
tester
• Testing of wear resistant materials in
high stress erosive or abrasive wear
conditions
– slurry pumps, mining applications,
dredging, loader buckets, etc.
• Testing of mineral abrasiveness in a
slurry or in dry conditions
– high rotation speed: up to 2000 rpm
(20 m/s in the sample tip)
– large abrasive size: 0-10 mm
– suitable for testing of metal bars or
plates, thick and thin coatings,
elastomers, and hybrid materials
– possibility to edge protection
– flow conditions vary in 4 sample levels
® requires sample rotation

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 (HVPI)
• Developed for the model verification and to identify the basic
mechanisms influencing the impact wear and failure behavior of
materials
– various angles and impact energies; projectile speed: 30…200 m/s
– suitable for various materials: metals, coatings, elastomers, hybrids, ...
– projectiles: metallic or ceramic ball bearing balls, cylinders, bullets, and rocks
– video recording: high speed camera NAC MEMRECAM up to 80 000 fps or
LaVision StrainMaster 3D DIC systems (high and low rate)
Trap wall
Target
assembly
Speed
measurement
device Smooth bore
Pressure
control
Pressurized
air tank
Specimen

High Velocity Particle Impactor
Rubber Impact wear resistant steel 500 HV

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

Surface fatigue wear
• Attached to Servohydraulic
Instron mechanical testing
machine
• 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

Focused Ion Beam Scanning Electron
Microscope (FIB-SEM) Zeiss Crossbeam 540
GEMINI II SEM column
• Double condenser system: high resolution at low voltage and high current
Capella FIB column
• High Ga+ beam current allows fast milling process; high resolution with low current
• SEM imaging in real-time
Multi gas injection system (Multi-GIS)
• Deposition and enhanced milling (Pt, C, SiO2, XeF2)
• Charge compensation (N2) for non-conductive samples
Detectors
• Imaging: SE, inlens SE and EsB, STEM
• Analysis: 3D EDS (Oxford, XMaxN silicon-drift detector, 80 mm2)
– Low energy analysis (incl. Be)
– Productive count rates even at low beam currents
Electron beam induced current (EBIC) method
Combines the powerful imaging performance of the FESEM with the superior
processing ability of the FIB -> 3D nano-workstation

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
• Alicona InfiniteFocus G5 3D profiler
• Veeco WYKO NT1100 optical profilometer
• Optical and stereo microscopes
• Retsch AS 200 analytical sieve shaker
• Precica XB4400 ja XT1220 weighers

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

TWC International Wear Seminar
Tribological challenges in industrial applications
28.10.2015 in collaboration with
Kulumiskustannukset hallintaan suunnittelulla ja
uusilla materiaaleilla 16.9.2015, Tampere

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

Tampere Wear Center activities and research equipment 2015

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