<p>Sawing is a critical operation in the wood industry, where guided saw systems play a key role in enhancing cutting precision and extending tool life. However, the guide pads used in guided circular saws—typically made from cast Babbitt alloy—are prone to significant wear over time. This results in frequent replacements, elevated maintenance costs, and operational downtime. This study investigates copper-based composite materials as potential alternatives to Babbitt alloys, aiming to improve wear resistance and tribological performance. The proposed composites incorporate solid lubricants—nickel-coated graphite (NCG), manganese sulfide (MnS), and calcium fluoride (CaF<sub>2</sub>)—and are fabricated via powder metallurgy with varying proportions of each additive. Their performance was evaluated using pin-on-disk and abrasive wear tests. Among the tested formulations, the composite containing 5&#xa0;vol.% NCG and 6&#xa0;vol.% CaF<sub>2</sub> demonstrated the most promising results, exhibiting the lowest coefficient of friction (COF) and wear rate. These improvements are attributed to the formation of a stable tribolayer during operation. Specifically, this composite achieved a 68% reduction in COF and a 66% decrease in wear rate compared to conventional Babbitt alloy. In three-body abrasion tests, wear loss was reduced by 46%. Although MnS contributed to lubrication, its weak bonding with the copper matrix led to increased wear, limiting its effectiveness. Conversely, oil impregnation of the composite significantly enhanced lubrication retention, leading to an 83% reduction in COF and an 88% reduction in wear rate compared to Babbitt. These findings demonstrate the potential of hybrid, self-lubricating Cu-based composites as viable replacements for traditional Babbitt alloys in high-wear applications. Their superior wear resistance, lower friction, and reduced reliance on external lubricants make them particularly well suited for improving the efficiency and service life of guided saw systems.</p>

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Development of Novel Composite Material to Replace Babbitt in Industrial Applications

  • A. Torkghashghaei,
  • S. Gélinas,
  • C. Blais

摘要

Sawing is a critical operation in the wood industry, where guided saw systems play a key role in enhancing cutting precision and extending tool life. However, the guide pads used in guided circular saws—typically made from cast Babbitt alloy—are prone to significant wear over time. This results in frequent replacements, elevated maintenance costs, and operational downtime. This study investigates copper-based composite materials as potential alternatives to Babbitt alloys, aiming to improve wear resistance and tribological performance. The proposed composites incorporate solid lubricants—nickel-coated graphite (NCG), manganese sulfide (MnS), and calcium fluoride (CaF2)—and are fabricated via powder metallurgy with varying proportions of each additive. Their performance was evaluated using pin-on-disk and abrasive wear tests. Among the tested formulations, the composite containing 5 vol.% NCG and 6 vol.% CaF2 demonstrated the most promising results, exhibiting the lowest coefficient of friction (COF) and wear rate. These improvements are attributed to the formation of a stable tribolayer during operation. Specifically, this composite achieved a 68% reduction in COF and a 66% decrease in wear rate compared to conventional Babbitt alloy. In three-body abrasion tests, wear loss was reduced by 46%. Although MnS contributed to lubrication, its weak bonding with the copper matrix led to increased wear, limiting its effectiveness. Conversely, oil impregnation of the composite significantly enhanced lubrication retention, leading to an 83% reduction in COF and an 88% reduction in wear rate compared to Babbitt. These findings demonstrate the potential of hybrid, self-lubricating Cu-based composites as viable replacements for traditional Babbitt alloys in high-wear applications. Their superior wear resistance, lower friction, and reduced reliance on external lubricants make them particularly well suited for improving the efficiency and service life of guided saw systems.