Cu/MoS2 composite material was formed by a novel powder-molding technique, which is termed the compression shearing method at room temperature (COSME-RT). Cu/MoS2 sample mechanical and tribological properties and microstructures were investigated. Samples were prepared using five different MoS2 concentrations between 0 to 20 vol.%. No unwanted compounds were generated by the Cu and MoS2 because a high temperature is unnecessary in COSME-RT. Scanning electron microscopy observations confirmed that the MoS2 particles were dispersed homogeneously in the Cu host matrix. The indentation hardness of Cu/MoS2 with 0, 1.0 and 5.0 vol.% MoS2 was higher than 1.6 GPa, and is higher than that formed by conventional powder metallurgy methods and a pure Cu plate. The indentation hardness of the Cu/MoS2 decreased with increasing MoS2 concentration. In contrast, the lubricating performance of MoS2 became more pronounced at 5.0 vol.% or above. The coefficient of friction of Cu/MoS2 with 5.0, 10 and 20 vol.% MoS2 was ~0.20, and is the same as for MoS2 in air. The sample coefficient of friction was maintained because of lubrication by forming a transferred film of wear debris that contained MoS2. Cu/MoS2 had a low coefficient of friction, but maintained its material strength at 5.0 vol.% MoS2.
The particles contained in the lubricating oil carry detailed and important information about the condition of the machine. The information may be deduced from particle shape, composition, size distribution and concentration. Particles eroded from the surface of an oil wetted component in any centralized lubrication system upon examination give specific and accurate information. The operating wear modes prevailing in the machine are determined with the examination of the lubricant in circulation. Analytical and experimental studies were undertaken to assess the deleterious effect of contaminants present in lubricant on the performance of critical equipment in steel plant. The study involves the findings of typical characteristics developed in the oil wetted components on account of contaminants. Morphology of worn out particles, change in chemistry of lubricant and the presence of contaminants in the centralized system was optimized. The experimental methods include quantification of total ferromagnetic particles through direct reading and analytical ferrography, particle size in a laser diffraction particle counter and deleterious particles present in the lubricant through an Oil View Analyser instrument and an inductive couple plasma unit. The above condition based analytical techniques were used to predict the overall health of the critical equipment located in different units of steel plant.
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