23rd International Colloquium Tribology - January 2022 463 An experimental study and numerical modelling of nanocomposite coating wear in sliding contact Professor Zulfiqar A Khan NanoCorr, Energy & Modelling Research (NCEM) Group, Department of Design & Engineering, Bournemouth university UK 1. Abstract This paper presents an experimental investigation and numerical modelling of reciprocating wear behaviour of nanocomposite coatings. This study employed u-shaped geometrical profiles to assess and calculate energy distribution along the interfacial contact by incorporating the Archard density factor. Both energy and mechanics equations were utilised to develop a mechano-wear model for characterisation of sliding wear behaviour in nanocomposite coatings. This study found that Nickel-Graphene demonstrated higher wear resistance compared to other composite coatings. These models are presented and are significant for predicting wear failures to mitigate machine idle time and reduce maintenance costs. Several coating failure mechanisms have been reported [1] including electrochemical decay. Earlier work considered optimisation of materials to include thickness of thin coating and surface texture at the interface during interactive components to avoid and mitigate electrochemical induced coating failures. Further a summary of significant models which have incorporated elastic energy release in relation to pressure and a new Khan-Nazir I model, shown below, with inclusion of mechanistic approach has been presented [1]. Where v c = Poisson ratio of coating, E c = young’s modulus of coating, = film thickness, Mc = blistering induced film-substrate system bending moment, p = blister pressure, = critical pressure. Khan-Nazir II model has been proposed and reported [2] for advanced numerical predictions in reciprocating contacts with incorporated effects of hardness of material and load configuration and has shown higher accuracy in compared to classical models [3]. Where = corrosion current density, F = Faraday’s constant, ρ = coating density, K = specimen material’s electrochemical equivalent, A s = area of the specimen, = corrosive wear volume loss, = wear rate, = Archard factor density, S = synergistic factor. In this work a reciprocating tribo-test configuration is employed to investigate newly developed nanocomposite coatings. Four selected composite coatings and test parameter are presented with experimental observation and discussion alongside their pre and post-test surface texture. Scanning Electron Microscopy and Energy Dispersive Spectroscopy were employed for both surface and constituents’ analyses. Grain sizes have been noted to corelate to coatings’ tribo performance. This study included surface quality in terms of roughness characteristics, co-efficient of friction and rate of wear in conjunction with energy attribute for the development of numerical models. Simulation results in terms of wear volume and friction coefficient and Archard loading factor are presented. A kinetic depth profile approach has been adapted to study and develop corresponding wear depth kinetics profiles (WDKP) [4]. New equations for mechano-wear analysis of nanocomposite coatings have been developed [4] and are discussed within the context of 2D predictive modelling. 2. Keywords Nanocomposite coatings, sliding contact, wear, simulation, modelling References [1] Nazir, M.H. and Khan, Z.A., 2017. A review of theoretical analysis techniques for cracking and corrosive degradation of film-substrate systems. Engineering Failure Analysis, 72, 80-113. [2] Kasar,A.K., Bhutta, M.U., Khan, Z.A. and Menezes, P.L., 2020. Corrosion performance ofnanocomposite coatings in moist SO2 environment. International Journal of Advanced Manufacturing Technology, 106 (11-12), 4769-4776. 464 23rd International Colloquium Tribology - January 2022 An experimental study and numerical modelling of nanocomposite coating wear in sliding contact [3] Nazir, M.H., Khan, Z.A., Saeed, A., Siddaiah, A. and Menezes, P.L., 2018. Synergistic wear-corrosion analysis and modelling of nanocomposite coatings. Tribology International, 121, 30-44. [4] Nazir, M.H., Khan, Z.A., Saeed, A., Bakolas, V., Braun, W. and Bajwa, R., 2018. Experimental analysis and modelling for reciprocating wear behaviour of nanocomposite coatings. Wear, 416-417, 89-102. Links https: / / www.researchgate.net/ lab/ NanoCorr-Energy-and- Modelling-NCEM-Research-Group-Zulfiqar-A-Khan