An innovative evaluation of microstructure and tribological behavior of AISI 1060 and CuZn37Pb2 under laboratory and complex working conditions

Wear is a significant industrial issue caused by the interaction of multiple complex factors rather than solely by material properties. CuZn37Pb2 and AISI 1060 steel are particularly susceptible to wear due to extensive industrial applications. This study developed a wear test tool, machined on a horizontal lathe, for testing under dry and lubricated conditions. A tribological comparison was conducted between the lathe test and a tribometer, examining factors like surface roughness, load, sliding speed, wear track diameter, track width, contact temperature, wear loss, and wear rate relative to the friction coefficient. Experiments were performed with torques ranging from 25 to 100 N, speeds of 0.30, 0.40, and 0.50 m/s, and wear track diameters of 4, 6, 8, and 10 mm. Worn surfaces and wear tracks were analyzed using optical microscopy and SEM-EDS. The influence of temperature (50 °C to 200 °C) on friction properties was studied, showing that sample morphology and test type greatly affect tribological response. Despite a wear rate calculation error below 8.12%, results indicated differences between laboratory and real-world tribological responses. This study enhances wear understanding by examining numerous previously unstudied characteristics and shows that, although wear cannot be entirely eliminated, it can be significantly minimized. Laboratory testing provides prototypes for industrial challenges, effectively linking academic research with industry needs.