Effect of Applied Force on Friction, Wear, and Microstructural Characteristics of 1040 Carbon Steel Pin Sliding on Alumina Disc

The vast majority of research publications focused on metal-to-metal sliding leading to friction, wear, and microstructural changes. Less attention is paid to the metal–ceramic friction and wear studies. Alumina inserts or coatings are applied to steel parts in machinery where low friction and wear resistance are critical, such as in linear guides and slide ways. Steel backing plates with alumina friction materials are often used for high-performance brake systems. The alumina ceramic component enhances the wear resistance and thermal stability of the break pads. Inserts made of alumina ceramic are frequently used in combination with steel for improved wear resistance, extended tool life, and efficient cutting operations. The aim is to investigate the influence of applied normal force 1040 carbon steel pin against an alumina ceramic disc and investigate friction, wear, microstructural characteristics, and wear mechanisms. Frictional force and wear rate were found to increase with increasing applied force of 10, 20, and 30 N and sliding velocity m/s, respectively, at 1.05, 1.83, and 2.62. SEM analysis has shown that abrasive and adhesive wear is prevalent. The observed slight transition tendencies from the constant coefficient of friction at 10 N to increased values with fluctuations at 20 and 30 N indicate a shift in wear mechanisms. The deeper grooves observed at 2000× magnification suggest severe wear at 30 N force, 2.62 m/s velocity.