Tampere Wear Center & Research equipment 2014

Tampere Wear Center&

Research Equipment

Kati ValtonenProject Manager

Tampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

Tampere University ofTechnology (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

Department of Materials ScienceInternationally high-level know-how on all materials based on

strong interdisciplinary basic research

Department of Materials Science• 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

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), VITO, TEKNIKER, the University of Sheffield, the University ofSouthampton, the University of Manchester, Luleå University ofTechnology, and Tallinn University of Technology. Of these, NRC, AC2Tand the University of Southampton have also been recently targets ofresearch 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

– Optimization, prediction and design guidelines for improved wear life ofnovel 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 andperformance 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 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 slidingtest rig, Single disc refiner, Pin-on-plate,Biomaterial crusher, Block-on-ring, Rubber wheelabrasion testers, etc.

• Tribology and machine elements test rigs: Testrigs for journal, thrust, and rolling bearings, FZG,Twin-disc test rig, Fretting wear and fatigue testrigs, 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-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

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

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

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 tumblerrotate, 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 typeerosion tester

• Testing of wear resistant materials formining and dredging pumps

• Testing of mineral abrasivity in slurryor 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 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• 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 wallTarget

assemblySpeed

measurementdevice

Smooth bore Pressurecontrol

Pressurizedair tank

Specimen

• Projectiles: e.g. metallic or ceramic ballbearing 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 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

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

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 afterevery step

• 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

Analytical TransmissionElectron Microscope JeolJEM 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• 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 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

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

SETEC 14SAMPE Europe TechnicalConference & Table TopExhibition10.-11.9.2014 Vapriikki,Tampere

Scientific conference for Smart andfunctional textiles, Well-Being, Thermalcomfort in clothing, Design, ThermalManikins and Modelling7.-9.9.2014 Tampere Hall, Tampere

www.tut.fi/mol

NORDTRIB 201614.-17.6.2016Aulanko, Hämeenlinna,Finland

Tampere University of TechnologyDepartment of Materials Science

Tampere Wear Center

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

Tampere Wear Center & Research equipment 2014

Technology

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