Experimental and Numerical Investigation of Wear Behavior of Monel 400 Alloy under Different Load and Speed Conditions

In this study, the wear behavior of Monel 400 alloy under different load and speed conditions was investigated using both experimental tests and numerical simulations. Wear tests were carried out using tungsten carbide (WC) ball with high hardness and abrasiveness. In the experiments, it was observed that there was a significant increase in the wear rate with the increase in applied load and speed. It was determined that especially at high loads, the material loss on the surface accelerated and more distinct wear marks were formed on the contact surface. The simulations performed were modeled based on Archard's wear law and verified with the experimental data obtained. According to the results obtained by simulation, the stress on the abrasive ball surface increases as speed and force increase. A maximum error rate of 12.30% was calculated between the simulation results and the experimental data, which shows that the finite element model is quite reliable in wear predictions. For example, in the wear tests carried out at a speed of 50 mm/s, a 168.4% increase in material volume loss occurred when the load was increased from 30 N to 50 N. This finding reveals the significant effect of the load on wear mechanisms. The studies show that the developed finite element model is successful in calculating wear deformations. In addition, results supporting that Monel 400 is a material with high wear resistance and can be used in applications requiring wear resistance in particular have been obtained. Future studies can be expanded to include different abrasive materials, changing environmental conditions and more complex loading scenarios.