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stages of wear, but none is available. Photographs are scattered through published papers and handbooks and are of some value only when properly described and understood. Engineers must therefore solve most wear problems themselves by analysis of worn surfaces and wear debris from existing machinery and wear testers. Guidelines for selecting wear-resisting materials and for indirectly selecting lubricants are given in the next section using the methods of product analysis.
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34.5 MATERIAL-SELECTION PROCEDURE
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The previous sections have established the important point that selecting materials for wear resistance requires a study of the details of wear in order to determine which of the several conventional properties of material can best resist a particular mode of wear. The best way to proceed, therefore, is to examine the most appropriate wear system (including the solids, the lubricant, and all the wear debris), such as an old product being redesigned or a wear tester. The best tools to use are microscopes, with some photography. The most useful microscope is a stereozoom type with a magnification range of 1 to 7 , with 5 or 10 eyepieces and a 100-W movable external light source. Stereo viewing gives a perspective on the shapes of surface features, such as grooves, folds, flakes, etc. The next most useful tool is the scanning (reflecting) electron microscope (SEM). The novice should use this instrument in conjunction with optical microscopes because the SEM and optical devices produce very different pictures of surfaces. Frequently the most useful SEM observations are those done at low magnification, between 20 and 200 , although it is fun to see surfaces at 20 000 . The virtue of the SEM is that very rough surfaces can be seen without the high regions and low regions being out of focus, as occurs in optical microscopy. The major problem is that the SEM usually accepts only small specimens [for example, 1 2 in (12.5 mm) thick by 2 in (50 mm) in diameter], and the surfaces must be clean because the SEM requires a vacuum (about 10 5 torr). For a more detailed analysis of surface chemistry and substrate composition, an SEM with an x-ray dispersion (EDAX, etc.) attachment can be used. The operation of these instruments requires some combination of skill and expensive automation. Optical metallurgical microscopes may be useful as well, but usually not in the conventional bright-field, reflected-light mode. These microscopes often have several special objectives for phase contrast, polarized light, interference, and dark field, all requiring skill in use and in the interpretation of results. Sometimes it is useful to obtain a topographic profile of worn surfaces. This can be done with the stylus tracer used in conventional surface-finish measurement, but it should be connected to a strip-chart recorder. It is the surface shape rather than a numerical value of surface finish that is most useful. Traces should be made in several places and in several directions during the progression of wearing, if possible. A major precaution to observe in analysis of the strip-chart data is that the representation of the height of surface shapes is often magnified from 10 to 1000 times greater than is the horizontal dimension. This leads to the sketching of surfaces as very jagged peaks upon which no one would care to sit. Actually, solid surfaces are more like the surfaces of a body of water in a 10-mi/h breeze. Having examined a wear system, the designer can proceed through Table 34.3 and make a first attempt to select a material for wear resistance.
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Downloaded from Digital Engineering Library @ McGraw-Hill (www.digitalengineeringlibrary.com) Copyright 2004 The McGraw-Hill Companies. All rights reserved. Any use is subject to the Terms of Use as given at the website.
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