Due to extreme working conditions of mining conveyors, which contaminate gear oil with solid particles, their transmissions are exposed to intensive abrasion, scuffing, and even rolling contact fatigue (pitting). These effects shorten gear life. To prevent their occurrence, a wear-resistant coating can be deposited on gear teeth. The resistance to abrasive wear, scuffing, and pitting was investigated and reported in the article. Simple, model specimens were used. Abrasive wear and scuffing were tested using a pin-and-vee-block tribosystem in sliding contact. A cone–three-ball rolling tribosystem was employed to test pitting. The material of the test specimens (pins, vee blocks, cones) was 18CrNiMo7-6 case-hardened steel. Two types of DLC (Diamond-like Coatings) coatings were tested, W-DLC and W-DLC/CrN. The vee blocks and cones were coated. Two industrial gear oils were selected to lubricate the specimens: one with a mineral and one with a synthetic PAO (polyalphaolephine) base, as pure oil or contaminated with solid particles from a coal mine. The results show that, to minimize the tendency to abrasion, scuffing, and pitting of specimens made of 18CrNiMo7-6 steel, the W-DLC/CrN coating should be deposited. This coating also gives very good protection when the lubricating oil is contaminated.

The transmissions of mining conveyors are exposed to very harsh conditions. These are primarily related to the contamination of the gear oil with hard particles coming from coal and lignite, which can cause intensive abrasive wear, scuffing, and even pitting, limiting the life of gears. One of the ways to prevent this problem is the deposition of a wear-resistant coating onto gear teeth. However, a proper choice of gear oil is an important issue. The abrasion, scuffing, and pitting tests were performed using simple, model specimens. A pin and vee block tester was employed for research on abrasion and scuffing. To test pitting, a modified four-ball pitting tester was used, where the top ball was replaced with a cone. The test pins, vee blocks, and cones were made of 18CrNiMo7-6 case-hardened steel. A new W-DLC/CrN coating was tested. It was deposited on the vee blocks and cones. For lubrication, three commercial industrial gear oils were used: A mineral oil, and two synthetic ones with polyalphaolefin (PAO) or polyalkylene glycol (PAG) bases. The results show that, to minimize the tendency forabrasion, scuffing, and pitting, the (W-DLC/CrN)-8CrNiMo7-6 tribosystems should be lubricated by the PAO gear oil.

This article presents an outline of a method of planning an experiment developed by Taguchi for the optimisation of processes and as an example of its application in the optimisation of parameters of a ball-cratering method. Abrasive wear tests were performed on chosen antiwear physical vapour deposition coatings with the optimum work parameters of friction node. (The test friction node is created by the rotating ball and the immobile sample disc that is pressed against it and an abrasive slurry is drip fed into the contact zone.) Then the factor of resistance to abrasive wear was calculated based on the evaluation of their resistance to abrasive wear. The Taguchi optimisation method was used in order to devise and verify the methodology of the abrasive wear research of physical vapour deposition coatings deposited using cathodic arc evaporation on two differently prepared substrates. A series of resistance tests to abrasive wear performed using ball-cratering method was conducted in accordance with the test plan based on the Taguchi design. The variable test parameters were load, the speed of ball rotation and sliding distance. A measuring device, an optical microscope, was used to take pictures and measure the diameters of the wear traces visible in the form of craters received after the performance of tribological tests. The purpose of this research was to devise a method for testing the resistance of antiwear physical vapour deposition coatings deposited on tools and machine parts to abrasive wear (performed using the ball-cratering method) by applying the Taguchi optimisation method. The experiments were carried out using the combination of tribological test parameters based on the nine experiments (L9) using Taguchi orthogonal design with variable three test parameters of load, the speed of ball rotation and sliding distance. The results of the abrasive wear test performed using ball-cratering method on duplex and non-duplex coatings were successfully verified using the Taguchi optimisation program. Optimisation of the tribological test parameters based on the Taguchi method has been found to be very efficient and convenient for the investigation of the abrasive wear rate of the duplex and non-duplex coatings.

Identification of changes occurring on the working surface of lubricated gears using analytical equipment, e.g., an FE-SEM scanning electron microscope with an EDS microanalyzer, a WLI interferometric microscope, or a GDEOS optical discharge spectrometer, enables the characterisation of wear mechanisms of this surface. Definition of the phenomena occurring on the surface of tribo-couples after scuffing tests enables a comparative analysis of scuffing resistance and surface properties of the micro- and nanostructure, and elemental composition of the tested gears. Recognition and analysis of the wear mechanisms occurring on the working surface of gears will reduce the risk of damage and losses resulting from the need for maintenance and repair. The study concerned the working surfaces of gears made of 17HNM and 35HGSA steels on which a W-DLC/CrN coating was deposited. Shell Omala S4 GX 320 commercial industrial oil with a synthetic PAO (polyalphaolefin) base was selected for the lubrication of the gears. Tribological tests employed an FZG gear scuffing under severe conditions test method and they were carried out on a T-12U test rig for cylindrical gear analysis.

The aim of this work was to obtain biochar materials from plant biomass and to determine the changes occurring under the conditions of the pyrolysis process and physical activation, as well as to characterize the physicochemical characteristics of the produced products in terms of their practical use. The pyrolysis process was carried out at a temperature of 700 °C, under the flow of a protective gas, i.e., carbon dioxide, at a rate of 5.0 L/min. The pyrolysis processes were carried out in the absence and presence of an activating agent. For ecological safety, physical activation using water vapor was chosen. In the next stage of the work, biochars were produced and subjected to detailed physicochemical analysis. A scanning electron microscope with energy-dispersive SEM/EDS was used to determine the microstructure and changes in the chemical composition of the biochars. FTIR spectrophotometry was used to identify the functional groups present in the structures of biochars and to indicate changes occurring in the biomass during pyrolysis. Meanwhile, Raman spectroscopy was used to assess the ordering of the biochar structures based on the identification of spectral signals. The description of the specific surface areas of the biochars was made possible by studies conducted using a physical and chemical adsorption analyzer. Based on the obtained research results, the elementary structure, surface development, presence of functional groups on the surfaces of biochars and changes in the structure before and after activation with water vapor were determined. It was found that the biochars had functional groups, a well-developed specific surface area that increased after activation with water vapor, micropores and mesopores, as well as changes in structure under the influence of physical activation. It has been shown that the presence of functional groups influences the hydrogen sulfide sorption capacity.

The aim of the study was to investigate effect of Ti/TiB₂ composite composition and manufacturing technology parameters on the tribological behaviour of AlCrN coating-composite system. The AlCrN coating was deposited by PVD (Physical Vapour Deposition) method. The composites were manufactured by spark plasma sintering (SPS) from three variants of powders mixtures: Ti with TiB₂, Ti6Al4V with TiB₂ as well as Ti with B, using (five) different sintering temperatures. For each of the developed coating-composite systems, the wear resistance was evaluated using ball-on-disc SRV tester, at six temperatures (from room temperature up to 900 °C). The results confirmed that high-temperature wear resistance of the coating–substrate combination depends on Ti/TiB₂ composite composition and manufacturing technology parameters. In the case of uncoated composite, two processes manage the wear at high temperatures: cracking propagation and surface oxidation. The presence of AlCrN coating on the composite surface protects the surface against deep cracking and surface oxidation. The composites of Group I, sintered at 1250 °C from a mixture of pure Ti and TiB₂ (50/50 wt.% ratio) as well as Group III, sintered at 1350 °C from a mixture of pure Ti and B allow the achievement of a satisfactory surface quality, a high adhesion of the PVD coating and moderate wear at high temperatures. However, the composite made of pure Ti and B seems to be a better solution for temperatures exceeding 600 °C.