An abrasion tester is used to erode the surface of materials to determine their durability, with various test methodologies and equipment designs complying with ASTM standards. Different types of abrasion test equipment include a rotating ball, Crock Meter, and Falling Sand Abrasion Tester. The dry rubber wheel abrasion test is the most common approach to testing abrasion resistant materials. Abrasion testing is important for creating strong materials, improving manufacturing processes, and building brand recognition.
An abrasion tester is a device designed to gradually or rapidly erode the surface from a solid material to determine the life of the material or the life of the coatings it has. Materials an abrasion tester is often used on include metals, ceramics, plastic composites, and thin-film coatings on cutting tools and bits. Testing common surface materials such as laminate flooring, paints, varnishes, and more can also be the focus of abrasion testing.
There are dozens of different test methodologies and equipment designs for operating an abrasion tester. Almost all of them voluntarily comply with various levels of technical standardization established by the American Society for Testing and Materials (ASTM), an international organization founded in the year 1898. The levels of testing covered by the ASTM guidelines range from known minor surface tests such as scratch-and-rub tests, to heavier abrasion and wear tests. The Crock Test is also a feature of the Abrasion Tester, which is based on ASTM standards that simulate the repeated rubbing action of human fingers and forearms across a surface.
There are several types of abrasion test equipment used to test durability. One option employs a rotating ball with a dead weight that is placed against a surface. A slurry of abrasive or diamond sand is then introduced between the ball and the surface to test the cutting tool coatings. The Crock Meter is another method used to test the transfer of color from fabrics and painted surfaces, or how much the toner in a copier image will smear. These devices use an acrylic scrubber in the shape of a human finger that scrubs back and forth across a surface in a four-inch (100-millimeter) interval.
The Falling Sand Abrasion Tester is another less used version of these machines. It employs a slow process that works by dropping abrasive particles through a guide tube onto a surface to consume them. It can take up to 159 gallons (600 liters) of sand particles impacting the surface before wear effects are noticed.
The most common approach to testing abrasion resistant materials is probably the use of the dry rubber wheel abrasion test, which complies with ASTM guideline G-65. This is used to determine scratch abrasion, or low levels of surface degradation, by rolling a rubber wheel against a surface and introducing sand particles between the two. This test is low-impact and does not alter the shape of the abrasive material used, unlike high-stress abrasion test equipment which causes abrasive particles to fracture into smaller pieces as they cut into the surface.
Abrasion testing processes are important as they are critical to making strong materials. The more durable a material surface is, the more consumers are willing to pay for it and the better the manufacturing process becomes. The company’s reputation and brand recognition are often built around their materials which are more durable than those of major competitors. Furthermore, the inclusion of guarantees in product claims is supported by the standardized tests that the abrasion results produce.
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