Material loss can result through sliding contact between solids, primarily due to wear process. Failure of interlocking asperities in contact, which can occur as a fracture-induced or plastic shearing mechanism, is a significant contributor in material wear. We developed an analytical model to predict asperity junction failure mechanisms as a function of material properties (fracture toughness and shear strength) and geometrical parameters (asperity height and width). The failure causes fracture-induced and plastic shearing below and above a threshold aspect ratio, respectively. This was validated by a wide range of configurations and materials using both finite element simulations and documented data from literature. Graphical Abstract: [Figure not available: see fulltext.].
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We thank anonymous reviewers for insightful comments and suggestions on earlier drafts of this work, which helped to improve the quality of the manuscript.
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