An Innovative Evaluation of the Friction and Wear Behavior of Ferrous and Non-Ferrous Metals Under Lab and Lathe Wear Tests

Wear is a persistent challenge in industrial applications, stemming from the interaction of numerous complex and interrelated factors. CuZn37Pb2 and AISI 1060 steel are particularly susceptible to wear due to their extensive industrial applications. To address this problem and enhance the scientific literature, it is essential first to understand and analyze the impact of these interconnected factors and their interactions through experimental investigations that consider the maximum number of available factors. This study developed a new wear test tool, machined on a horizontal lathe, to conduct tests under both dry and lubricated conditions. A tribological comparison was made between the lathe test and a tribometer, considering the interplay of various factors. The study examined and compared initial surface roughness, load, sliding speed, wear track diameter, track width, contact temperature, wear loss, and wear rate in relation to the friction coefficient. Experiments were performed at torques ranging from 25 to 100 N, at speeds of 0.30, 0.40, and 0.50 m/s, and with wear track diameters of 4, 6, 8, and 10 mm. The worn surfaces and wear tracks of each sample were analyzed using optical microscopy, XRD patterns, and SEM–EDS. This work investigated the influence of temperature (ranging from 50 to 200 °C) on the friction properties of the two alloys. It was found that the morphological structure of the sample and the type of test significantly impact the tribological response of the surfaces, each interacting uniquely with varying contributions from the tribological parameters. Despite the wear rate calculation error being less than 45.14% in both tests, the findings indicated that the tribological response under ideal laboratory conditions differs from that in real-world environments. The study provided significant advancements in understanding and analyzing the wear phenomenon by addressing the largest number of accessible characteristics, many of which had not been previously studied. The findings also revealed that while it is challenging to eliminate wear entirely, it can be significantly reduced. Moreover, field wear tests can be extrapolated through laboratory experiments, offering prototypes for industrial challenges and bridging the gap between academic research and industry needs.