A finite element analysis (FEA) based wear algorithm model is presented to predict sliding wear behavior of a composite cobalt-based (Stellite 6) alloy. This study aims to provide an understanding of FEA model behavior using: (a) free-mesh, (b) composite material microstructure, and (c) wear test conditions of loading and geometry which are consistent with ASTM G133-02. Results indicate that the wear model using free-mesh is able to predict wear in composite alloy within the limits of experimental deviation using a suitable kD (wear-rate) value. The rationale for the differences in the experimental setup and FEA model calculations is discussed in terms of the role of wear debris, wear mechanisms, and ball wear.

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