3.1 Characterization of the SP-NBSC superalloy
Shot-peening treatment caused the change of microstructure and surface morphology. The surface morphology of the SP-NBSC superalloy was observed by the three-dimensional integral microscopy (Fig. 3a). It can be found that many impact pits were distributed on the specimen surface induced by the steel ball with high speed. The enlarged morphology showed that the impact pits seemed like irregular circles with the averaged depth about 20 µm (Fig. 3b). The surface roughness of the SP-NBSC superalloy was about 9.35 µm, which was more than ten times that of the AS-NBSC superalloy. The increased surface roughness indicated that the serious plastic deformation occurred on the specimen surface. Moreover, the microstructure of the cross-sectional region near the shot-peened surface showed that shot-peening treatment introduced dislocation bands and dislocation networks beneath the surface (Fig. 3c). Shot-peening treatment improved the surface hardness of the NBSC superalloy from 370 Hv to 551 Hv, the improvement of the surface harness was mainly attributed to the severe plastic deformation and strain hardening [34].
3.2 Tribological performance
In order to investigate the tribological performance of the SP-NBSC superalloy, the friction tests under different temperatures and normal loads were carried out. It can be observed that the COF evolutions under different test temperatures exhibited dramatical differences (Fig. 4a). At room temperature (about 25 ℃), the initial COF reached to about 0.7 and lasted for about 60 mins, then it decreased to about 0.6. When the temperature increased to 600 and 700 ℃, the COFs were more stable and about half of that at room temperature, it can be deduced that high temperature promoted the tribo-chemical reaction that was beneficial to friction reduction. Besides, the averaged COFs during the steady wear period decreased with the increase of test temperature, but there was little difference in COF when the test temperatures were 600 and 700 ℃ (Fig. 4c). However, the evolution of COF showed great difference under different normal loads at 600 ℃ (Fig. 4b). It can be observed that when the normal load was 15 N, the COF increased to about 0.65 rapidly and lasted for about 30 mins, then it decreased to about 0.4 sharply. The larger COF during the running-in period at 15 N may be resulted from the instability of the formed glaze-layer under lower normal load. With the continuous sliding, the COF would decreased finally, which might indicate that the stable glaze-layer formed. Similarly, when the normal load was 10 N, the evolution of COF also exhibited the characteristics of piecewise decline. It can be deduced that larger normal load promoted the formation of stable tribo-layer. Moreover, the averaged COF increased from 0.3 to 0.4 when the normal load decreased from 20 N to 10 N (Fig. 4d). Therefore, it can conclude that both temperature and normal load have a great influence on COF. Besides, the averaged COFs of the SP-NBSC superalloy under different loading condition showed no great differences compared with those of the AS-NBSC superalloy, which may be due to the competing effects between hardness and roughness.
After the friction tests, the morphologies of the wear track on the SP-NBSC superalloy were analyzed. The macroscopic morphology of a representative wear scar showed that an annular trace formed on the specimen surface after the friction test (Fig. 5a). In order to analyze the characteristics of wear tracks quantitatively, the cross-sectional morphologies were measured by using the three-dimensional integral microscopy at eight different locations (marked in Fig. 5a). The cross-sectional morphology at a representative location was shown in Fig. 5b, the circular profile was ascribed to the uneven distribution of contact stresses according to Hertz theory. When the normal load was 20 N, both the widths and depths of the wear tracks were lower at 600 and 700 ℃ compared with those at room temperature, which indicated that high temperature promoted the wear reduction (Fig. 5c). Besides, the depths of the wear tracks increased when the normal load increased from 10 N to 15 N at 600 ℃, but the widths of the wear tracks did not change too much when the normal load varied from 15 N to 20 N (Fig. 5d). For all the friction tests, the depths of the wear scar were all greater than 35 µm, which were larger than the thickness of the plastic layer induced by shot-peening treatment. Therefore, it can be inferred that the shot-peening induced plastic layer has been completely worn out after two hours of friction tests.
The wear rates of the SP-NBSC superalloy under different loading conditions were calculated to further investigate its tribological performance. It could be observed that the wear rate of the SP-NBSC superalloy was about 11.21 × 10− 8 mm3/(N·mm) at room temperature, which was almost three times that at 600 ℃ and 700 ℃. Besides, the wear rate of the SP-NBSC superalloy at 700 ℃ was about 20% higher than that at 600 ℃, which may be due to the deterioration of the mechanical properties at higher temperature. Moreover, the wear rates showed little difference when the normal load varied from 10 N to 15 N, but the wear rate increased as the normal load increased to 20 N, which was consistent with the results of the AS-NBSC superalloy [26]. In summary, although shot-peening treatment resulted in the increased surface roughness, the wear rate of the SP-NBSC superalloy showed little difference in comparison with the AS-NBSC superalloy, and the decreased wear rate at high temperature was may be ascribed to the formed glaze-layer during the friction test.
3.3 Analysis of the wear scar
The tribological behavior of the SP-NBSC superalloy showed great difference under different test conditions, which could lead to distinguished wear damage. To explore the effects of temperatures and loads on the wear damage, the morphologies of the wear tracks on the SP-NBSC plate were investigated by using SEM. It could be found that some micro cracks were distributed on the surface of NBSC after the friction test at room temperature (Fig. 6a), and severe surface peeling occurred due to the large contact stress. Besides, there were many flake-like wear debris attached to the specimen surface, and some deep furrows were generated. It can be inferred that adhesive and abrasive wear was the main wear mechanism for the SP-NBSC superalloy at room temperature. As the test temperature increased to 600 ℃, the surface material was heavily oxidized, parts of the oxides were worn off and crushed into fine wear debris (Fig. 6b). The wear track was smoother compared with that at room temperature, which exhibited the typical characteristic of glaze-layer [35]. Besides, some mild scratches were also distributed on the specimen surface. It can be deduced that the SP-NBSC superalloy underwent more severe abrasive wear at 600 ℃ than room temperature. When the test temperature was 700 ℃, the surface morphologies of the wear track showed different characteristics, which was smoother than that at room temperature and 600 ℃ (Fig. 6c). The formed oxides on the specimen surface seemed dense, and mild scratches were formed on the specimen surface with little granular wear debris attache. Therefore, the abrasive wear was the main wear mechanism when the temperature increased to 700 ℃.
Furthermore, the effects of normal loads on the wear damage of SP-NBSC superalloy at 600 ℃ were also investigated. When the normal load was 15 N, some spalling pits can be observed on the wear track, which was mainly induced by the large frictional stress (Fig. 7a). Then the materials removed from the surface will be crushed into fine wear debris under the action of large contact stress. After the friction test, it can be found that some flake-like wear debris were retained on the worn region. As the normal load decreased to 10 N, many shallow furrows were observed on the wear track, the direction of the furrows was consistent with the sliding direction (Fig. 7b). Besides, there were some elongated spalling pits near the furrows. It can be deduced that the abrasive wear became the main wear mechanism when the normal load decreased from 20 N to 10 N.
It has been reported that the formed glaze-layer during high temperature friction process promoted the reduction of COF and wear rate. Therefore, the chemical composition of the glaze-layer under different test conditions were investigated by using EDS, and the element percentage in the wear track were shown in Table 2. It can be found that the contents of oxygen were almost 20% when the test temperature was 600 ℃ and 700 ℃, while the content of oxygen was 4.34% after the friction test at room temperature. It can be deduced that both the friction induced heat and the high temperature environment promoted the surface oxidation during the high temperature friction process. The composition of the formed oxides had a great influence on the tribological performance of SP-NSBC superalloy. In order to further analyze the material composition of the glaze-layer, Raman spectra analysis under different test conditions were performed, as shown in Fig. 8. There were nearly five different peaks located at 360 cm− 1, 550 cm− 1, 680 cm− 1, 830 cm− 1 and 1060 cm− 1, respectively. The strongest peak appeared at around 830 cm− 1 corresponded to CrxOy and WOx[36, 37]. The peak at around 1060 cm− 1 referred to (Ni,Co)O [38, 39], and the peak of 680 cm− 1 appeared at elevated temperature indicated the existence of Co3O4 and NiCrO4 [38, 40]. The peaks CrxOy also appeared at 360 cm− 1, 550 cm− 1 [38, 41]. It can conclude that different kinds of metal oxides (including Ni, Cr, Co, and W) were generated at elevated temperature, that contributed to the reduction of friction and wear [18, 22, 42]. Although friction induced heat at room temperature also cause the surface oxidation, the amount of the oxides was too small to improve the tribological performance of the SP-NBSC superalloy. Moreover, the formation of Co3O4 and NiCrO4 at high temperature also played an important role in the improvement of its tribological performance.
Table 2
The chemical composition and element percentage of the wear scar under different test conditions (w.t.%)
Test condition F / T | C | O | Al | Cr | Co | Ni | W |
20 N / 25 ℃ | 10.76 | 4.34 | 5.21 | 6.41 | 9.52 | 59.21 | 4.55 |
20 N / 600 ℃ | 6.41 | 19.93 | 4.54 | 5.54 | 8.00 | 49.68 | 5.90 |
20 N / 700 ℃ | 4.27 | 19.94 | 5.05 | 6.13 | 8.86 | 49.90 | 5.85 |
15 N / 600 ℃ | 2.95 | 21.10 | 4.84 | 5.47 | 10.67 | 51.58 | 3.39 |
10 N / 600 ℃ | 3.45 | 18.98 | 4.95 | 5.26 | 9.25 | 55.51 | 2.60 |
3.4 Cross-sectional morphology
According to the above analyses, high temperature promoted the formation of glaze-layer, which was composed of different metallic oxides and contributed to the prominent tribological behavior of SP-NBSC. The cross-sectional morphology beneath the wear track was analyzed by using SEM to investigate the microstructure of the glaze-layer, as shown in Fig. 9. It can be observed that the two-layer structure formed after the high temperature friction test, a plastic deformation layer was generated, the γ/γ’ microstructures of which were seriously distorted due to the large contact stress. Above the deformation layer, there was a glaze-layer formed, which was originated from the compacting and sintering of wear debris. The glaze-layer can prevent the direct contact between the friction pair, and contribute to the low COF and wear rate due to the low shear strength of the metal oxides. However, no glaze-layer was formed at room temperature, it was because that the weak oxidation cannot provide enough oxides to form a continuous film, and the initially formed film will be continuously destroyed by the large frictional stress (Fig. 9a). In contrast, the tribofilm formed at elevated temperature was dense, and the thicker tribofilm could effectively protect the substrate (Fig. 9b-9e). The γ/γ’ microstructure beneath the glaze-layer was more distorted at 700 ℃ than that at 600 ℃, which may be induced by the degradation of mechanical properties at higher temperature. When the test temperature was 600 ℃, both the thickness of glaze-layer and plastic layer increased with the increase of normal load. On the one hand, large load resulted in high contact stress and promoted the plastic deformation of substrate. On the other hand, wear debris was easy to wear off and compact on the specimen surface, which will promote the formation of the thicker glaze-layer.
3.5 Wear mechanism
According to the above analyses, the wear mechanism of SP-NBSC superalloy at high temperature was proposed (Fig. 10). The wear process of SP-NBSC superalloy can be divided into two periods, i.e., the running-in period and stable wear period. During in the running-in period, multiple rough peaks of the specimen surface were in contact with the Si3N4 ball, the actual stress will be higher compared with the AS-NBSC superalloy due to the increased surface roughness of the SP-NBSC superalloy. The surface material was worn off due to the large frictional stress and then formed wear debris (Fig. 10a). At the same time, the friction induced heat and high temperature environment caused the surface oxidation. With the continuous friction, the surface oxidation and wear intensified, and a part of the wear debris accumulated and be trapped between the friction pair. The trapped wear debris would be sintered and compacted on the surface and formed a glaze-layer (Fig. 10b). The glaze-layer was composed of different kinds of metal oxides (including Ni, Cr, Co, and W), which prevented the direct contact of the friction pair. Furthermore, these oxides had good anti-wear and anti-friction properties, thereby improving the tribological performance under high temperature conditions [15, 29, 31, 42].
The tribological performances of SP-NBSC superalloy depended on the applied normal load and test temperature during the friction process, which led to the difference in wear mechanism. At room temperature, there was weak oxidation in the contact region, and no glaze-layer was formed to protect the substrate, the main wear mechanism was adhesion and abrasion. When the test temperature increased to 600 ℃ and above, severe oxidative wear occurred, and a glaze-layer was formed on the surface of SP-NBSC superalloy due to the sintering and compacting of wear debris. The formed glaze-layer could avoid the direct contact of the friction pair and effectively reduce friction and wear. However, the wear mechanism under high temperature conditions was not exactly the same. At 600 ℃, both adhesive wear and abrasive wear existed during the friction process, but the abrasive wear became prominent with the decreased normal load. When the test temperature increased to 700 ℃, the main wear mechanism was abrasive wear and oxidative wear, which may be attributed to the different composition of the formed glaze-layer.