Fretting corrosion of lubricated tin plated copper alloy contacts: Effect of temperature

The fretting corrosion behaviour of lubricated tin plated copper alloy contacts at ambient and elevated temperatures is addressed in this paper. At 27 °C, lubrication is very effective and the contact resistance remains stable for several thousand fretting cycles whereas at elevated temperatures (155 °C) the performance of lubricated contact is not appreciable. Surface profile and surface roughness confirm that the lubricated contacts have a smoother profile and experience a lesser damage at the contact zone at ambient as well as at elevated temperatures. The mechanism of fretting corrosion of tin plated contacts appears to be similar with and without lubrication at all the temperatures studied. The difference in performance of the lubricated contacts at ambient and elevated temperatures is due to the faster wear rate of tin coating at elevated temperatures. Oxidation of the contact zone of the lubricated contacts is prevented at all temperatures studied. The study concludes that lubrication is effective in improving the life of the tin plated copper alloy contacts under fretting conditions at ambient temperatures whereas at elevated temperatures lubrication provides only a marginal improvement in performance. The decrease in performance of lubricated tin plated contacts at elevated temperatures is due to the higher wear rate of tin coating and not due to evaporation of the lubricant.     

Surface segregation of Au–Pd alloys in UHV and reactive environments: Quantification by a catalytic atom probe

The surface composition of an Au-62 at% Pd alloy has been studied by means of a catalytic atom probe (CAP) before and after exposures to nitric oxide (NO) at temperatures ranging from 300 to 573 K for 20 min. Subsequent CAP analysis at 100 K revealed a considerable surface enrichment in Pd (to ∼80 at%) after exposure at 573 K. This is correlated with the occurrence of NO dissociation, and the formation of strong Pd–O bonds at the surface. Blank experiments in ultra-high vacuum reflect the surface composition of the bulk material, in excellent agreement with electron microprobe analysis. At 573 K, no detectable surface segregation occurs in the absence of NO adsorption for the times and temperatures studied. However, classical Metropolis Monte-Carlo simulations performed with a semi-empirical potential on the Au₄₀Pd₆₀ (1 1 1), (1 1 0) and (1 0 0) systems show surface enrichment of gold at equilibrium. This suggests that the temperatures of the clean surface segregation experiments are too low to reach equilibrium within times of the order of hours.     

Synergy between corrosion and wear of electrodeposited Ni-P coating in NaCl solution

An immersion block-on-ring tester was employed in this study to investigate the interaction between wear and corrosion of electroplated Ni-P coating in 5% NaCl solution. The weight loss and the coefficient of friction of the specimen under different bath temperatures and overpotentials were measured. The results showed that at temperature of 50 °C and overpotential of +600 mV_SCE, which was within the transpassive region of its polarization curve, a severe synergy between corrosion and wear was observed. However, at lower temperatures and overpotentials, the interaction between wear and corrosion was hardly noticed.     

High temperature fretting wear behavior of WC-25Co coatings prepared by D-gun spraying on Ti-Al-Zr titanium alloy

Detonation gun (D-gun) spraying is one of the most promising spraying techniques for producing wear-resistance coatings. A thick layer (about 0.3 mm thickness) of WC-25Co with high hardness was covered on Ti-Al-Zr titanium alloy by D-gun spraying and the fretting wear behavior of WC-25Co coatings was studied experimentally on a high precision hydraulic fretting wear test rig. An experimental layout was designed to perform fretting wear tests at elevated temperatures from room temperature (25 °C) to 400 °C in ambient air. In the tests, a sphere (Si₃N₄ ceramic ball) was designed to rub against a plane (Ti-Al-Zr titanium alloy with or without WC-25Co coatings). It was found that the fretting running regimes of WC-25Co coatings were obviously different from those of Ti-Al-Zr titanium alloy. The mixed fretting regime disappeared in WC-25Co coatings, and the boundaries in the running condition fretting map (RCFM) showed hardly any change as temperature increased. The worn scars were examined using a laser confocal scanning microscope (LCSM), scanning electron microscope (SEM), energy dispersive X-ray spectroscopy (EDS) and X-ray photoelectron spectroscopy (XPS). The results showed that the coefficients of friction (COF) of WC-25Co coatings at elevated temperatures were nearly constant in the partial slip regime and very low in the steady state. The fretting damage of the coatings was very slight. In the slip regime, the WC-25Co coatings exhibited a good wear resistance, and the wear volume of the coatings obviously decreased with increasing tested temperature. The fretting wear mechanisms of WC-25Co coatings were delamination, abrasive wear and oxidation wear at elevated temperature. The oxide debris layer formed at higher temperature was denser and thicker on top of WC-25Co coatings, thus providing more surface protection against fretting wear, which played an important role in the low fretting wear of the coatings.     

Tribological behavior of Stellite 21 modified with yttrium

Cobalt-base alloys have found a wide variety of tribological applications particularly at elevated temperatures or in corrosive environments in many industries, such as aerospace, automotive, power and gas turbines. One of the standard Co-base alloys, Stellite 21, is used predominantly to resist the synergistic effects of corrosion and mechanical attack, especially at elevated temperatures and continuing efforts have been made to improve its properties. One approach is to add reactive elements, such as yttrium, in order to beneficially affect its oxidation behavior.Research was conducted to investigate the effects of Y additions on Stellite 21 on its microstructure, mechanical behavior, and high-temperature wear performance. These studies employed various experimental tools, such as micro-mechanical probe, XRD, SEM, EDS, and high-temperature tribometer. The effects of Y addition on the properties of the oxide film formed on Stellite 21 were also investigated using grazing XRD and nano-mechanical probing techniques.It has been demonstrated that Y additions benefited the wear behavior of Stellite 21, especially at elevated temperatures. The oxide scale developed at 600 °C also showed markedly enhanced mechanical properties when Y was alloyed to the alloy.     

Simultaneous measurement of CO and CO2 at elevated temperatures by diode laser wavelength modulated spectroscopy

One single semiconductor distributed-feedback (DFB) laser is used to demonstrate the possibility of simultaneous measurements of CO and CO₂ at elevated temperatures. Wavelength modulation spectroscopy with second-harmonic detection is used to improve the detection sensitivity and accuracy. The concentrations of CO and CO₂ are determined from the WMS-1-normalized absorption-based WMS-2f signal peak heights of a proper line pair of CO and CO₂ near 6357.814 cm⁻¹ and 6357.312 cm⁻¹, which are selected using some line-selection criterions for the target temperature range of 300–1000 K. The CO and CO₂ concentrations measurements are within 2.86% and 2.69% of the expected values over the tested temperature range 300–1000 K. The minimum detectable concentrations of CO and CO₂ at 1000 K are 250 ppm m and 280 ppm m respectively.     

Effect of temperature on the fretting corrosion of tin plated copper alloy contacts

The effect of temperature on the fretting corrosion behaviour of tin plated copper alloy contacts in the temperature range of 25–185 °C, is addressed in this paper. The change in contact resistance with fretting cycles at various temperatures was determined. The contact zone after fretting corrosion test was analyzed using laser scanning microscope, X-ray diffraction (XRD), scanning electron microscopy (SEM) and X-ray spectrometry (EDX), to assess the surface profile, phase content, morphology and compositional changes across the interface. The study reveals that temperature has a greater influence on the extent of fretting corrosion of tin plated copper alloy contacts. The softening of tin is responsible for the extended region of low contact resistance observed at 85 °C. The increase in thickness and the resistance of Cu–Sn intermetallic compounds (IMCs) is responsible for the decrease in surface roughness and the drastic increase in the contact resistance at higher temperatures. The study suggests that the tin plated copper alloy contact system should be considered as copper alloy/IMC/Sn/SnO₂ instead tin plated copper alloy. During fretting corrosion test at elevated temperatures, once the top surface layers are worn out, the contact interface is transformed from tin versus tin-to-tin-intermetallic versus tin-intermetallic. The study concludes that tin plated copper alloy contacts are not suitable for high temperature applications.     

Influence of counterbody material on wear of ta-C coatings under fretting conditions at elevated temperatures

The high temperature tribological performance of tetrahedral amorphous carbon coatings has been analyzed at elevated temperatures up to 250 °C in air against three different counterbody materials—steel 100Cr6, α-alumina and silicon nitride. The results show that the counterbody material influences the friction and wear behavior and therefore coating life time strongly. This effect is well known for these coatings at room temperature under dry environmental conditions, equivalent to conditions above 100 °C when water molecules desorb from the surface. However, the sharp difference in tribological performance between silicon nitride on the one hand and alumina and steel on the other hand cannot be understood in this context. Analyzing the friction behavior during the running-in phase, it is evident that only alumina and steel form a stable interface with constant low friction and relatively low wear rates. Silicon nitride forms an unstable interface with fluctuating COF and relatively high wear rates due to its own inherent tendency to tribo-oxidation.     

Fabrication and characterization of ZnO thin film for hydrogen gas sensing prepared by RF-magnetron sputtering

A ZnO thin film-based gas sensor was fabricated using a SiO₂/Si substrate with an integrated platinum comb-like electrode and heating element. The structural characteristics, morphology, and surface roughness of the as-grown ZnO nanostructure were investigated. The optical properties were examined by UV–vis spectrophotometry. The film revealed the presence of a c-axis oriented (0 0 2) phase of 20.8 nm grain size. The sensor response was tested for hydrogen concentrations of 50, 70, 100, 200, 400, and 500 ppm at operating temperatures ranging from 250 °C to 400 °C. The sensitivity toward 50 and 200 ppm of hydrogen at the optimum operating temperature of 350 °C were about 78% and 98%, respectively. The response was linear within the range of 50–200 ppm of hydrogen concentration. Our results demonstrated the potential application of ZnO nanostructure for fabricating cost-effective and high-performance gas sensors.     

Alkyl Imidazolium Ionic Liquids as Friction Reduction and Anti-Wear Additive in Polyurea Grease for Steel/Steel Contacts

Five room temperature ionic liquids (ILs), 1-butyl-3-methylimidazolium hexafluorophosphate (L-P104), 1-hexyl-3-methylimidazolium hexafluorophosphate (L-P106), 1-octyl-3-methylimidazolium hexafluorophosphate (L-P108), 1-decyl-3-methylimidazolium hexafluorophosphate (L-P110), and 1-hexyl-3-methylimidazolium tetrafluoroborate (LB106) were studied as 1 wt% additives of polyurea grease for steel/steel contacts. Their tribological behaviors as additives of polyurea grease for steel/steel contacts were evaluated on an Optimol SRV-IV oscillating reciprocating friction and wear tester and an MRS-1J (G) four-ball tester at room and high temperatures. The friction test results showed that the ILs, as 1 wt% additives in polyurea grease for steel/steel contacts, had better friction reduction and anti-wear properties at high temperature than at room temperature, and ILs can significantly improve the friction reduction and anti-wear properties of polyurea grease compared with base grease containing 1 wt% of zinc dialkyldithiophosphate (T204). The excellent tribological properties are attributed to the formation of a surface protective film composed of FeF₂, nitrides, and compound containing the P–O bonding on the lubricated metal surface by a tribochemical reaction. The ordered adsorbed films and good miscibility of ILs with the base grease also contributed to the excellent tribological properties. Wear mechanisms and worn steel surfaces were studied by a PHI-5702 multifunctional X-ray photoelectron spectrometer and a JSM-5600LV scanning electron microscope.     

Several plasma diffusion processes for improving wear properties of Ti6Al4V alloy

Different kinds of diffusion processes, plasma nitriding, oxidizing and oxynitriding as of a combination of other two, have been applied to Ti6Al4V alloy to evaluate the effect of treatment times (1 and 4 h) and temperatures (650 and 750 °C) on wear properties of the alloy. It was observed that a hard modified layer was produced on the surface of the alloy after each diffusion process. While TiN and Ti₂N phases form in the modified layer with plasma nitriding, mainly TiO₂ phase forms after plasma oxidizing treatment. The wear tests performed at different normal loads showed that all treated samples, except for nitrided and oxidized at 650 °C for 1 h, exhibited higher wear resistance than untreated Ti6Al4V alloy. The plasma nitrided samples showed adhesive wear. On the other hand, while the plasma oxidizing samples displayed adhesive wear at lower loads, wear mechanism changed to abrasive wear as the load increased because the oxide film which covers the surface was broken during the sliding at higher loads.     

Influence of aging treatment on microstructure, wear and corrosion behavior of a nickel base hardfaced coating

In this work nickel based hardfacing alloy (Colmonoy 5) was deposited on 316 L (N) stainless steel substrate to study the effects of aging treatment on coating microstructure, wear and corrosion properties. Coatings, deposited through plasma transferred arc (PTA) welding process, were aged at 923 K for 5000 h. Microstructural characterization studies carried out by scanning electron microscopy (SEM) and transmission electron microscopy (TEM) revealed the coarsening of dendrites and precipitation of Cr₂₃C₆ particles in the aged coating. The wear behavior of the as deposited and aged coatings was compared in room temperature (RT) and high temperature (823 K) under dry sliding wear condition (pin-on-disc configuration). At RT, aged coating experienced more wear loss when compared to as-deposited. At high temperature, the wear loss was almost same with similar operating wear mechanisms (tribo-oxidation) for both as-deposited and aged coating. From pitting corrosion studies, it was found that aged coatings are more prone to pitting when compared to the as-deposited coatings.     

Wear behaviour of hardfaced Fe-Cr-C alloy and austenitic steel under 2-body and 3-body conditions at elevated temperature

Fe-based hardfacing alloys are widely used to protect machinery equipment exposed to different loading situations where abrasives play a dominant role in restricting lifetime of tools. Wear at elevated temperatures is superposed by the effect of oxidation of the wearing surface. In view of the above, two hardfacing alloys based on Fe-Cr-C incorporating Nb, Mo and B to ensure improved performances at elevated temperature were deposited onto mild steel under optimised gas metal arc welding (GMAW) condition. 2-body erosive wear behaviour was evaluated from room temperature up to 650 °C under 30° and 90° impact angle. For 3-body impact/abrasion conditions tests were done with a specially designed cyclic impact abrasion tester (CIAT) at room temperature and 600 °C. The wear behaviour of the hardfacings was compared with austenitic stainless steel. Results indicate that 2-body erosive wear rate of the hardfacing increases with test temperature and with increase in impact angle, whereas wear behaviour of the austenitic stainless steel is non-sensitive to the testing temperature at normal impact. In 3-body impact abrasion testing similar behaviour can be seen; cyclic tests in CIAT at enhanced temperatures result in breaking of coarse carbides, whereas wear mechanisms of the austenitic steel result in massive abrasion and formation of a mechanically mixed layer (MML).     

Effects of carbon content on the high temperature friction and wear of chromium carbonitride coatings

Chromium nitride-based coatings are often used in application at high temperature. They possess high wear and oxidation resistance; however, the friction coefficient is typically very high. Therefore, we doped CrN coatings by carbon with the aim to improve tribological properties at elevated temperature, particularly to lower the friction. CrCN coatings were prepared by cathode arc evaporation technology using constant N₂ flow and variable C₂H₂ flow. The coatings with a thickness of 3-4 μm were deposited on hardened steel substrates and high-temperature resistant alloy. The carbon content varied from 0 at.% (i.e. CrN) up to 31 at.%. The standard coating characterization included the nano-hardness, adhesion, chemical composition and structure (including hot X-ray diffraction). Wear testing was done using a high temperature tribometer (pin-on-disc); the maximum testing temperature was 700 °C. The coatings with carbon content 12-31 at.% showed almost identical tribological behaviour up to 700 °C.     

Corrosion and wear of 6082 aluminum alloy

The corrosion and corrosive wear resistance of 6082 wrought aluminum alloy against 410 stainless steel counterface in 0.01 M NaCl solution with different concentrations of sodium molybdate dihydrate solution (0, 0.01, 0.1 and 0.5 M), were studied. The experimental results indicated that the increase in sodium molybdate dihydrate acted as an inhibitor in the 0.01 M NaCl solution resulting in a significant decrease in the corrosion current, meaning improved corrosion resistance. During the corrosive wear under free corrosion conditions of 6082 aluminum alloy specimens against 410 stainless steel counterface, the addition of sodium molybdate dihydrate inhibitor, leads to a decrease in friction coefficient of the examined pair of materials. The dominant wear mechanisms of the aluminum alloy were mainly observed to be plastic deformation and abrasion. These wear mechanisms coexisted with pitting corrosion phenomena, on the surface of this alloy.     

Residual stresses in TiN, DLC and MoS2 coated surfaces with regard to their tribological fracture behaviour

Thin hard coatings on components and tools are used increasingly due to the rapid development in deposition techniques, tribological performance and application skills. The residual stresses in a coated surface are crucial for its tribological performance. Compressive residual stresses in PVD deposited TiN and DLC coatings were measured to be in the range of 0.03-4 GPa on steel substrate and 0.1-1.3 GPa on silicon. MoS₂ coatings had tensional stresses in the range of 0.8-1.3 on steel and 0.16 GPa compressive stresses on silicon. The fracture pattern of coatings deposited on steel substrate were analysed both in bend testing and scratch testing. A micro-scale finite element method (FEM) modelling and stress simulation of a 2 μm TiN-coated steel surface was carried out and showed a reduction of the generated tensile buckling stresses in front of the sliding tip when compressive residual stresses of 1 GPa were included in the model. However, this reduction is not similarly observed in the scratch groove behind the tip, possibly due to sliding contact-induced stress relaxation. Scratch and bending tests allowed calculation of the fracture toughness of the three coated surfaces, based on both empirical crack pattern observations and FEM stress calculation, which resulted in highest values for TiN coating followed by MoS₂ and DLC coatings, being K_C = 4-11, about 2, and 1-2 MPa m^1/2, respectively. Higher compressive residual stresses in the coating and higher elastic modulus of the coating correlated to increased fracture toughness of the coated surface.     

Burgers vector determination in deformed perovskite and post-perovskite of CaIrO3 using thickness fringes in weak-beam dark-field images

The thickness-fringe method [Ishida et al., Philosophical Magazine 42 (1980) 453] for complete determination of the character of a dislocation Burgers vector has been performed in CaIrO₃ perovskite and post-perovskite deformed at high pressures and high temperatures. By selecting several main zone axes and determining the number of terminating thickness fringes at the extremity of a dislocation from a wedge-shaped thin-foil specimen in weak-beam dark-field transmission electron microscope (TEM) images, the Burgers vectors were unambiguously determined. The results demonstrate that [1 0 0] screw and edge dislocations on the (0 1 0) slip plane are dominant in the post-perovskite phase. Curved [1 0 0] and [0 1 0] dislocations and straight 〈1 1 0〉 screw dislocations on a potential (0 0 1) slip plane were identified in the perovskite phase as well as a high density of {1 1 0} twins. Low-angle tilt boundaries consisting of different groups of parallel edge dislocations on the {1 1 0} and (0 0 1) planes indicate diffusion-assisted climb in perovskite at high temperatures. The differences in dislocation microstructures could be due to activations of limited numbers of slip systems for post-perovskite and of a large number of multiple slip systems for perovskite, which may result in the strong crystallographic preferred orientation (CPO) in post-perovskite and the lack of CPO in deformed perovskite.     

Ionic liquids as lubricants for steel–aluminum contacts at low and elevated temperatures

Room temperature ionic liquids (ILs) are high performance fluids with a wide thermal stability range. In this work we present the first study of ILs as lubricants under a wide range of temperature conditions (−30, 100, and 200 °C). The tribological performance of the imidazolium ionic liquids 1-hexyl, 3-methyl (L106) and 1-octyl, 3-methyl (L108) imidazolium tetrafluoroborates have been compared with that of a mineral oil (MO) and the synthetic ester propylene glycol dioleate (PGDO) in pin-on-disk aluminum–steel contacts. ILs show lower friction and wear values than conventional oils at all temperatures. The lubricating performance depends on thermal stability, polarity of the molecules, their ability to form ordered adsorbed layers and the tribocorrosion processes, which take place at the interface. While the conventional oils MO and PGDO fail above 150 °C due to thermal decomposition, the longer alkyl chain L108 provides an effective surface separation at all temperatures. L108 only shows friction and wear increments at −30 °C in the presence of water, due to severe abrasion. While the more polar, shorter alkyl chain L106 shows severe wear at 200 °C due to aluminum fluoride wear debris formation by tribocorrosion reactions. The time for tribocorrosion to take place has been determined from friction increments and wear debris generation. Wear mechanisms are discussed on the basis of SEM, EDS, and XPS results.     

Corrosion of materials used as cutting tools of wood

According to the wood species and the type of metallic materials, the wear of woodcutting tools is very different. The metallic nature of cutting tools, the water and water-soluble components in the wood result in an electrochemical mechanism of corrosion. Of course, both a mechanical wear and an electrochemical action are responsible of the total wear of metallic tools. The objective of this study is to characterise the electrochemical action of the wood medium on the corrosion of the woodcutting tool materials.To carry out the corrosion tests, a corrosive medium is obtained by infusing wood shavings into water to obtain a juice of wood. In a second step, we have selected several metallic materials used in woodcutting and a wood specie, namely oak. Electrochemical measurements (R_p, E_corr and i = f(E) curve) were carried out during 24 h in a medium containing a water-soluble extract of oak (=an oak juice). The electrochemical behaviour of each metallic material was characterised and the morphology of the corroded surface was observed by SEM. It is shown that the electrochemical corrosion is not negligible and can be very important on cutting materials. Further experiments are in progress to characterise the effect of the mechanical wear by tribocorrosion measurements.     

Application of Taguchi method for determining optimum surface roughness in turning of high-alloy white cast iron

This paper focused on optimizing the cutting conditions for the average surface roughness (R_a) obtained in machining of high-alloy white cast iron (Ni-Hard) at two different hardness levels (50 HRC and 62 HRC). Machining experiments were performed at the CNC lathe using ceramic and cubic boron nitride (CBN) cutting tools on Ni-Hard materials. Cutting speed, feed rate and depth of cut were chosen as the cutting parameters. Taguchi L₁₈ orthogonal array was used to design of experiment. Optimal cutting conditions was determined using the signal-to-noise (S/N) ratio which was calculated for R_a according to the “the-smaller-the-better” approach. The effects of the cutting parameters and tool materials on surface roughness were evaluated by the analysis of variance. The statistical analysis indicated that the parameters that have the biggest effect on R_a for Ni-Hard materials with 50 HRC and 62 HRC are the cutting speed and feed rate, respectively. Additionally, the optimum cutting conditions for the materials with 50 HRC and 62 HRC was found at different levels.