The results of systematic studies of the electrospark alloying process with the introduction of dispersed materials into plasma of low-voltage pulsed discharges are presented. Technological methods have been developed for supplying the powder material straight into the treatment zone through a hollow electrode of an anode or from the side, with the electrode-anode periodically contacting the substrate of cathode. It has been established that under the same energy regimes, when powder materials were introduced into the discharge zone, the increase in the mass of the cathode per time unit increases from 10 to 15 times or more. This study presents the process of synthesis of carbide phases (TiC and WC) during electrospark alloying of steel substrates with electrodes made of Ti, W, and graphite, with additional supply powders of these materials into the processing zone. A process has been developed for the synthesis of ternary compounds, so-called MAX-phases: Ti₂AlC, Ti₂AlN and Ti₃SiC₂ by electrospark alloying with powder compositions TiAlC, TiAlN and TiSiC. These MAX phases exhibit a unique combination of properties that are characteristic of both metals and ceramics. Energy modes of the processing were optimized, which resulted in high-quality coatings with the maximum content of carbide phases and ternary compounds. It has been established that the energy of electrical pulses during electrospark alloying, when powders of materials are fed into the interelectrode gap, ranges from 0.8 to 3.0 J, depending on their thermal physical properties. High wear and corrosion resistant characteristics of C45 structural steel with such electrospark coatings are obtained. The wear of steel with coatings in comparison with uncoated steel decreased by an average of 5.5–6.0 times. It was estimated the high corrosion resistance of 40X13 steel coated with TiC and WC in 3% NaCl solution. The corrosion current for these coatings is 0.044 and 0.075 A/cm², respectively, and is significantly less than for coatings made of TiAlC, TiAlN, and TiSiC compositions. X-ray phase and optical metallographic microscopy analyses enabled the display of the amorphous-crystalline nature of the coatings.

Tribology is the branch of science and engineering that focuses on understanding friction, wear, and lubrication, which is essential for saving energy, improving performance, reducing vibration, and creating eco-friendly lubricants and wear resistance. Over the past decade, nanomaterials have captured the immense interest of tribology science. This review aimed to analyze how graphene and its derivatives can be incorporated into lubricants to enhance their properties, particularly in mitigating friction and wear. This is due to graphene’s excellent specific properties, such as a low friction coefficient, mechanical strength, high thermal and electrical conductivity, biocompatibility, high load-carrying capacity, wear resistance, and chemical stability. This study briefly introduces graphite, graphene, and graphene oxide, as well as presents graphene as a material for tribological applications. Among other things, the environmentally friendly possibilities of chemical reduction of reduced graphene oxide are analyzed here, as well as the macro-, micro-, and nano-tribological examination of graphene and its derivatives. Despite what is already known about graphene in tribology, further research is needed to gain a deeper understanding of development regarding integration with different materials, long-term performance, eco-friendly synthesis using green reducing agents, and comprehending how these approaches may affect systems at various scales.

Cereal straw is a biomaterial with great potential: about 144 million tons of biomass are grown annually in Europe. For any use of straw (fertilizer, biofuel, etc.), efficient chopping technology, i.e., the reliable and efficient operation of mobile or stationary choppers, is the key factor for further success. Since most of the straw is chopped at harvest time, the subject of the study is the wear of the combine’s chopping knives. Six blades of different materials and designs were tested under realistic conditions during wheat and rapeseed harvesting on 180 ha. The influence of hardness, composition, cutting edge angle, and position in the chopper on knife wear was analyzed. The study showed that the blades with the highest cutting edge hardness (568 ± 11 HV) and the lowest cutting edge angle (20.9°) had the lowest wear. The highest hardness of the induction hardened knives was due to the 0.42% carbon content of the steel. The study confirmed that wear was inversely proportional to the hardness of the cutting edge (the harder the cutting edge, the lower the wear) and directly proportional to the angle of the cutting edge (the higher the angle, the greater the wear). The SEM study showed that part of the tooth surface of the blades was covered by permanent deposits of the material to be shredded. This wear was not caused by the interaction between straw and blade but by microabrasive particles that contaminated the straw.

Most of the biomass of cereal straw is chopped and left on the field as organic fertilizer, but its conversion into fertilizer depends on the quality of chopping, which is influenced by the wear of the chopping blades. The aim of the study was to determine the influence of the contamination of the cereal straw on the wear of the combine chopper blades. The study was conducted during the harvest in 2022, when 30 ± 1% of the grain was lodged and contaminated with abrasive soil particles (poor conditions), and in 2023, when the straw was unlodged and clean (excellent conditions). Six sets of blades with different mechanical and geometric properties were selected. The results showed that the wear ranges were very different: 1.47–2.99 g/100 ha in 2022 and 0.72–2.14 g/100 ha in 2023. For micro-abrasive wear, the hardness of the blades (349–568 HV) and the cutting edge angle (20°–29°) were important factors of their wear resistance. When the clean straw was chopped, the influence of the blade hardness and cutting edge angle on wear was not significant, and the wear was less. The wear of the blades had a sinusoidal character, which was related to the position of the blades on the chopping drum. This character depends on the design of the chopper and not on the straw quality.

Steel and aluminum alloys are used to manufacture the bodies of bulk material handling machines. The aluminum body enables a higher load mass and thus reduces transport costs. However, the greater abrasion of aluminum alloys leads to more frequent repairs to the underside of the body, as the abrasion parameters of aluminum are lower. This study, which used three different methods to evaluate abrasive wear (erosive/impact wear, abrasive wear in the mass of the free abrasive and abrasion test according to ASTM G65), showed that the most significant influence on the wear of 3004 series aluminum is the grain size of the abrasive. Only under erosive/impact wear conditions with abrasive particles of 2.0–5.0 and 5.0–8.0 mm is aluminum competitive with Hardox 450 in terms of volumetric wear, with aluminum exhibiting 1.3–1.4 times the wear rate of steel. Tests on the abrasive mass of the grinding fraction in question have shown that the volumetric wear of aluminum is 0.2–2.3 times higher at very low contact loads. In contrast, aluminum wears 7.5 and 4 times more than steel in the ASTM G65 test (0.1–0.4 mm fraction) at low and medium contact loads. Only in exceptional cases is the aluminum floor of bulk material handling equipment competitive with hardened steel in terms of wear intensity.

Al₂O₃, Al₂O₃-graphite and Al₂O₃-ZrO₂ coatings were formed on the C45 steel rolls using atmospheric plasma spraying. The influence of graphite and zirconia addition on the surface morphology, phase composition and tribological properties under dry sliding conditions using 30 N load were analyzed. It was found that the addition of graphite or ZrO₂ slightly affected the fraction of the α-Al₂O₃ and γ-Al₂O₃ phases in the alumina coatings. The highest mass loss rate (~8.84 × 10⁻⁴ g/s) was obtained for the friction pair of C45 steel roll and steel plate. The friction coefficient of the Al₂O₃-graphite coating was slightly lower (up to 7%) compared to the coating of Al₂O₃-ZrO₂. However, the friction pair of Al₂O₃-ZrO₂ coating and steel plate demonstrated the highest wear resistance under dry sliding conditions. The increase in the wear resistance of the Al₂O₃-graphite and Al₂O₃-ZrO₂ coatings is due to the formation of tribofilm in the sliding contact zone.