Tampere Wear Center activities and research equipment 2015

Tampere Wear Center&

Research Equipment

Kati ValtonenProject Manager

Tampere University of TechnologyDepartment 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

Department of Materials ScienceInternationally 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 andMachine Elements

MaterialsCharacterization

Metals Technology Plastics andElastomerTechnology

Surface Engineering

Fibre MaterialsScience

Paper andPackaging

Ceramic Materials

Veli-Tapani Kuokkala

Veli-Tapani Kuokkala

Erkki LevänenHead of Department

Arto Lehtovaara

Jyrki Vuorinen

Pasi Peura

Petri Vuoristo

Jurkka KuusipaloMinnamari Vippola

TWC (Tampere Wear Center)

LAL (Laser Application Laboratory)

Department of Materials Science

TSCF (Thermal Spray Center Finland)

Tampere Wear Center - TWC

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 machineelements, 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 severalinternationally recognized partners, such as the National ResearchCouncil of Canada (NRC), the Austrian Excellence Center for Tribology(AC2T), Mines ParisTech, VITO, TEKNIKER, the University ofSheffield, 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 havealso been recently targets of research exchange.

• One example of TWC’s international activities is the recently foundedNordic Hard Rock Tribology Network, RockTrib, embracing several keyresearch 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, DalarnaUniversity, and VTT.

TWC projects 1/2• FIMECC BSA: Design beyond present codes

– Materials in Mining Industry: Optimization, prediction and design guidelines forimproved wear life of novel steels and metallic multimaterials

– Energy and Life Cycle Efficiency: Surface fatigue and extreme load carrying capacityof 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 jawcrusher, Impeller-tumbler, Erosion tester, High-speed slurry-pot type erosion tester, Cavitationerosion tester, High velocity particle impactor, Ball-on-block, Hammer mill, High-speed sliding test rig,Single disc refiner, Block-on-ring, Rubber wheelabrasion testers, etc.

• Tribology and machine elements test rigs: Test rigsfor 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-diskCommercial 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 apneumatic cylinder (200-500N)

• Pin does not come into directcontact with the disk at any time ®wear of the components due toabrasive ploughing and cutting onthe pin and disk surfaces

• During the test, the abrasive sizedecreases at different rates,depending on the pin-diskcombination.

• 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

Crushing Pin-on-disk

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 anddiameter 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

Uniaxial Crusher

Dual pivoted jaw crusher• A novel reduced-size laboratory scale

jaw crusher for studying themechanisms of abrasive wear duringmineral crushing

– Replaces/complements the standardizedtest ASTM G 81-83

• Key design features:– control of jaw movement without changing

the test geometry, enabling accurate controlof the compression-sliding ratio

– versatile instrumentation for monitoring thewear processes, including piezoelectric forcesensors, 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

Compressioncompression/sliding ratio 10:1

Slidingcompression/sliding ratio 1:8

Impeller-Tumbler Impact-AbrasiveWear Tester

• Simulates wear in mineral handling applications, such as earth movingmachinery and impactor plants.

• During the test, an impeller with three samples (75*25*10 mm) rotatesinside 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

Impeller-tumbler

High-speed slurry-pot type erosiontester

• Testing of wear resistant materials inhigh stress erosive or abrasive wearconditions

– slurry pumps, mining applications,dredging, loader buckets, etc.

• Testing of mineral abrasiveness in aslurry or in dry conditions

• Key design features:– 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 testerWear testing of materials and coatings at roomtemperature 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 ErosionUsing 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 tipfor cavitation testing.

Test parametersFrequency 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 ofmaterials

• Key design features:– 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

Targetassembly

Speedmeasurement

device Smooth borePressurecontrol

Pressurizedair tank

Specimen

High Velocity Particle Impactor

Rubber Impact wear resistant steel 500 HV

Ball-On-Block Impact WearTesting Device

• Ball-on-block is a high-energy impact wear testingdevice that produces repeatedly high-energyimpacts to the surface of the specimen

• Impacts are created by shooting a ball to thespecimen 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

Ball-On-Block

Hammer-mill Type Impact WearTesting Device

• Two rotating hammers• The abrasive is fed between the hammer and

the specimen from a container through afeeder 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 slidingconditions in modern paper-making processes

• Up to four samples can be testedat once

• Slurry composition adjustable• Automated slurry level

adjustment and several self-monitoring features ® test runscan be set up to run for days

• Wear rates are lower than thoseprovided by the ASTM G 65standard test

Surface fatigue wear

• Attached to ServohydraulicInstron mechanical testingmachine

• Holder moves after everystep

• Intender ball or spike

Other wear equipment

Dry Sand Rubber WheelAbrasion Testing Device

Slurry Abrasion Testing Device

Block-on-Ring

Tribology andmachine 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, [email protected] Lehtovaara, [email protected]

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

mailto:[email protected]


Thrust bearing test rigTest targets: evaluation of thrust bearingperformance- friction and power loss- load capasity- bearing materials and configurations- failure modes

Specifications:- rotating speed 0 – 2000 rpm- external lubrication unit with oil filtering andtemperature, flow and pressure control




Test targets: testing gear contact andlubrication properties- friction and power loss- 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- external lubrication unit with oil filtering andtemperature, flow and pressure control


FZG Gear test rig



Test targets: performance and durabilitytests of different power transmissioncomponents- 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


Power transmission test rig

Versatile measurement possibilities



Roller bearing test rig

Test targets: evaluation of roller bearingperformance- friction and power loss- lubricants, lubrication condition

Specifications- bearing outer diameter 90 mm- normal and axial loading- oil (bath) temperature control or- external lubrication unit with oil filtering andtemperature, flow and pressure control




Test targets: gear and rolling/sliding contacttesting- 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


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, [email protected] Lehtovaara, [email protected]

Complete contact fretting test rig



Sphere on plane fretting test rig

Test targets: Fretting experimentationwith Hertzian point contact- fretting fatigue- fretting wear- friction- partial and gross sliding conditions.

Specifications:Large contact radius: 0.2 … 0.5 mLoading frequency: 40 HzNormal force: 500…3300 NDisplacement amplitude: 5…60 µm

Contacts:Jouko Hintikka, [email protected] Lehtovaara, [email protected]




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 MicroscopeZeiss 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 ElectronMicroscope (FIB-SEM) Zeiss Crossbeam 540

GEMINI II SEM column• Double condenser system: high resolution at low voltage and high currentCapella FIB column• High Ga+ beam current allows fast milling process; high resolution with low current• SEM imaging in real-timeMulti gas injection system (Multi-GIS)• Deposition and enhanced milling (Pt, C, SiO2, XeF2)• Charge compensation (N2) for non-conductive samplesDetectors• 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 superiorprocessing ability of the FIB -> 3D nano-workstation

Analytical Transmission ElectronMicroscope Jeol JEM 2010

Analytical Transmission Electon Microscope (TEM)is equipped with an energy dispersive X-rayspectrometer (EDS) and digital camera system. Thismicroscope is used primarly for studing the structureand 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-rayspectrometer (EDS) with Si(Li) detectorGATAN 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 rate abrasionwith HSB

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 SystemsTwo independent LaVision StrainMaster 3D DIC systems that can be operatedindependently.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 mountingsystem

High rate system• 2 Cameras: Photron SA-X2

– 12 bit images, 1MPix maximum resolution. 12.500 fps at max.res. Higher fps at reducedresolution,e.g. 200kHz at 256*152.

– 16GB of internal memory, recording time around 0.7 to 10 seconds depending on theresolution and fps

• A rigid mounting system for the cameras and lights and high speed trigger unit

Digital Image Correlation

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)

Sprayingmethod

Processtemperature

(°C)

Particlevelocity

(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 SeminarTribological challenges in industrial applications28.10.2015 in collaboration with

Kulumiskustannukset hallintaan suunnittelulla jauusilla materiaaleilla 16.9.2015, Tampere

Tampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

www.tut.fi/molwww.tut.fi/twc

Tampere Wear Center activities and research equipment 2015

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