Mechanical wear is a major cause of metal component failure in industrial machinery. It occurs when physical forces acting on a component cause gradual material loss or damage to its surface. Unlike chemical or thermal degradation, mechanical wear is the direct result of friction, impact and repeated mechanical stresses, which are commonplace in many industries.
If left unmanaged, mechanical wear shortens component life and drives up maintenance costs. On top of this, it can also increase the risk of sudden equipment failure. Understanding the causes and preventive measures when it comes to mechanical wear is essential for engineers that want to design reliable and long-lasting systems.
Mechanical wear describes types of surface and subsurface damage caused by direct physical interaction between materials. Mechanical wear is most common in components such as bearings, gears, shafts, pump rotors, valve stems and turbine blades where surfaces are in constant contact under load. When looking deeper at mechanical wear, it can be separated into three main categories:
Mechanical wear can take place in different ways depending on the component and its function. Here are four main examples of where it can take place.
The consequences of unchecked mechanical wear are significant, leading to premature component failure and component downtime as a result of the need for maintenance and part replacement costs. Alongside this, mechanical wear directly reduces the efficiency of components due to roughened surfaces or leakage in rotating machinery. Finally, it presents potential safety hazards in critical applications such as aerospace actuators or high-pressure pumps.
Mechanical wear cannot be completely avoided, but it can be minimised through engineering controls. A well-maintained lubricating film reduces direct contact and lowers friction. Monitoring lubricant cleanliness also prevents abrasive particle ingress. If the application allows, using metals with higher hardness or fatigue strength can extend wear life, but base material selection can often be limited by weight, machinability or cost.
In light of this, surface engineering provides the most effective defence against mechanical wear. Protective coatings can add hardness, reduce friction and shield the base metal from direct damage without needing to compromise on material selection.
Traditional solutions like hard chrome plating and thermal spray coatings have been widely used for mechanical wear prevention, but each comes with limitations like porosity, uneven coverage, or environmental concerns.
Recent Chemical Vapour Deposition (CVD) coatings (such as tungsten/tungsten carbide composites) offer superior protection against mechanical wear. These coatings combine high hardness with exceptional toughness, resist cracking under repeated stress and can coat complex internal and external surfaces uniformly.
By creating a durable, pore-free surface barrier, CVD coatings can extend the life of critical parts facing mechanical wear and also reduce downtime/lower total operating costs across industries facing this issue.
Mechanical wear is a silent but costly threat to industrial reliability. By understanding its causes (abrasion, impact and surface fatigue) engineers can take proactive steps to prevent it. Through careful design and the use of advanced wear-resistant coatings, components can achieve longer service lives and improved operational efficiency.
Hardide’s nanostructured CVD tungsten carbide coatings are specifically engineered to combat mechanical wear, providing exceptional protection for components operating in high-stress and impact-prone environments. The method of coating also enables the complete uniform coating of complex geometry components that would be impossible for traditional methods like HVOF. For organisations seeking to extend component life whilst reducing maintenance costs, these coatings deliver proven performance in some of the toughest applications.
To find out more about the benefits of Hardide’s CVD coating and how it can extend the life of your components facing mechanical wear, download our guide below.