Characterization of the effects of embedded quartz layer on wear rates in abrasive wear

• The effects of embedded quartz layer on wear rates in abrasive wear were studied.
• Crushing pin-on-disc test simulates heavy abrasive processes, like rock crushing.
• Quartz forms an in-situ composite layer with the metal surface.
• The embedded quartz decreased the wear rate of 400–800 HV metals.
• For low-hardness metals (<400 HV), the embedded quartz increased the wear rates.

Understanding how the wear environment and the history of the wear surfaces affect wear and wear rates is extremely important in mineral processing and mining applications. Through this, the lifetime expectations of wear parts can be estimated more precisely in wear environments with constantly changing abrasive media. Certain mineral combinations can increase wear rates extensively compared to some others. The economical effects of unnecessary down-times are significant. In this study, the effects of embedded quartz layer on wear rates were investigated. Hard metals, metal matrix composites, and several types of steels were studied to find differences in their wear behavior. Running-in of the specimens was performed using quartz or granite abrasives to create surfaces with and without embedded quartz. Only granite was used as an abrasive in the actual wear tests. For low-hardness materials (<400 HV), the quartz running-in increased the wear rates in the actual wear tests, whereas for medium-hardness materials (400–800 HV) the wear rates were decreased. When the hardness of the tested material was higher than the hardness of quartz, the selection of running-in abrasive did not have an effect on the further wear rate. Characteristics of the embedded quartz layers on different substrates were further determined by scanning electron microscopy.