A study of three-body particle generation and subsequent pole tip recession in linear tape recording heads

The Pole Tip Recession (PTR) and transferred material (stain) are major causes of magnetic spacing losses in magnetic recording system. The recorded signal amplitude is only independent of the data being read if the spacing is zero. Thus, the level and more specifically the variation in head media spacing with device life must be a minimum to maximise signal output and minimised errors. It was the purpose of this research to isolate and identify the mechanisms responsible for pole tip recession using the Linear Tape Open format as an experimental platform, but the results have implications for any head where the tape-bearing surface is Al₂O₃/TiC (AlTiC).All experiments were conducted within a matrix of pressure and humidity, which encompassed the system operating extremes. Atomic force microscopy (AFM) was used to analyse the surface topography of the heads and monitor the development of PTR after 100, 1000 and 5000 passes of tape. Auger electron spectroscopy (AES) was employed to analyse the chemical changes on the surface of the heads after 5000 passes of tape and X-ray Photoelectron Spectroscopy (XPS) was used to identify the chemical changes that occurred at the head surfaces. Optical Microscopy was employed to identify the head surface changes before and after wear. Environment was found to have a significant influence on the head/tape interface. Head wear and PTR were highest at high temperature and humidity.Wear between the head and tape was found to transform the surface layers on the TiC grains in the tape-bearing surface to TiO₂. This process results in the production of TiO₂ fragments that become trapped in the recessed pole tip region, acting as three-body abrasive particles. The presence of Ti on the surface of head thin film region confirmed that the three-body particles originated from the head AlTiC ceramic. The TiO₂ (thickness and possible areal coverage) increased with the water content increase, wear of head increased in the high water content condition.     

The tribology of advanced digital recording (ADR) systems

The advanced digital recording system, a linear tape recording system is examined with respect to the tribology involved at the head/tape interface. Using atomic force microscopy (AFM), Auger elcetron spectrocopy (AES) and scanning Auger microscopy (SAM) surface characterisation techniques, several wear mechanisms are isolated: scratching, attributed to the polishing action of the tape asperities; microfracture then pullout of the Al₂O₃–TiC ceramic used as tape bearing surface; and ploughing due to three-body action of ceramic pullouts entrapped on the recessed poles. A ceramic differential wear is found to occur at the expense of the Al₂O₃ component, which therefore forms the ceramic recessed regions. The ceramic pullouts involved in the poles' three-body abrasion, however, appear to consist of TiC particles. A model for the ceramic wear mechanism is proposed. A transferred mixture of possibly magnetic pigments, binder and lubricant from the tape to the head is observed in the form of adhesive deposits. The iron component of this transfer is found in higher concentrations on the pole tips and the prominent part of the ceramic.     

Wear of Silicon Carbide in Sliding Contact with Lubricated Thin-Film Rigid Disk

Silicon carbide (SiC) is a potential ceramic material for recording heads, yet its tribological performance against lubricated thin-film rigid disks is not fully known. Square pins with a 100 mm radius spherical surface were made from hot pressed SiC, chemical vapor deposited (CVD) SiC, and Al₂O₃TiC, and tested with lubricated thin-film disks. The pin-on-disk tests showed that the region of contact on the spherical surface of the SiC and CVD-SiC pins wears away to form a circular wear plateau with smears in and around the plateau. The wear plateau is formed rapidly in the first 1000 drag revolutions and then very gradually grows in size with further revolutions. Analysis of the smears showed that a large fraction of the smears contained SiO₂ which had been oxidized from SiC due to high temperatures generated at the pin surface in contact with the disk. In contrast, tests with Al₂O₃. TiC pins did not show any formation of a wear plateau on the pins.     

Effects of fullerene C60 on the friction and wear characteristics of ceramics in ethanol

For the combinations of a pin of Si₃N₄ and five kinds of disk, the friction and wear test was carried out in ethanol, and in ethanol containing C₆₀ particles (1 wt%). A topographical analysis was also performed on the micro-asperities of the wear surfaces to estimate the behavior of C₆₀ particles, and the degree of surface damage. As a results, the following facts were found. (1) The addition of C₆₀ particles in ethanol decreased the wear rates of such ceramic disks as Al₂O₃, SiC and TiC and of the mating Si₃N₄ pins. (2) The addition of C₆₀ particles decreased the mean coefficient of friction for SiC, Si₃N₄, and TiC disks. (3) The wear rates of pin and disk depended on the topographies of worn surfaces such as the mean depth of micro-grooves, the mean tip radius of micro-asperities and so on.     

Influence of Al2O3 reinforcement on the abrasive wear characteristic of Al2O3/PA1010 composite coatings

In the present study, the abrasive wear characteristics of Al₂O₃/PA1010 composite coatings were tested on the turnplate abrasive wear testing machine. Steel 45 (quenched and low-temperature tempered) was used as a reference material. The experimental results showed that when the Al₂O₃ particles have been treated with a silane coupling agent (γ-aminopropyl-triethoxysilane), the abrasive wear resistance of Al₂O₃/PA1010 composite coatings has a good linear relationship with the volume fraction of Al₂O₃ particles in Al₂O₃/PA1010 composite coatings and the linear correlation coefficient is 0.979. Under the experimental conditions, the size of Al₂O₃ particles (40.5-161.0 μm) has little influence on the abrasive wear resistance of Al₂O₃/PA1010 composite coatings. By treating the surface of Al₂O₃ particles with the silane coupling agent, the distribution of Al₂O₃ particles in PA1010 matrix is more homogeneous and the bonding state between Al₂O₃ particles and PA1010 matrix is better. Therefore, the Al₂O₃ particles make the Al₂O₃/PA1010 composite coatings have better abrasive wear resistance than PA1010 coating. The wear resistance of Al₂O₃/PA1010 composite coatings is about 45% compared with that of steel 45.     

Pole tip recession in sandwich heads incorporating a FeTaN soft magnetic track

Pole tip recession (PTR) contributes to a growth in signal loss during the lifetime of sandwich recording heads used in helical scan recording. In this paper results are presented for PTR, measured by AFM, resulting from the cycling of Zr–CaTiO₃/FeTaN sandwich heads against commercial ME and MP tapes in Hi-8 recorders, at 30°C/90% rh and 22°C/80% rh. PTR is seen to be within acceptable levels for Hi-8 recording. Particles adhered to the soft magnetic track, and responsible for head staining, are investigated. An unusual wear pattern on the soft magnetic material is noted.     

Dry sliding wear mechanism for P/M austenitic stainless steels and their composites containing Al2O3 and Y2O3 particles

Austenitic stainless steels are used in applications demanding general corrosion resistance at room or moderate operating temperatures. However, their use is often limited by the relative softness of these materials and their suceptibility to wear and galling. The present investigation deals with the dry sliding wear behaviour of two P/M austenitic stainless steels (AISI 304L and 316L) and their composites containing two different ceramic particles (Al₂O₃ and Y₂O₃) and two different sintering activators (BN and B₂Cr). Unlubricated pin-on-disc wear tests were carried out. Wear mechanisms were analysed by means of scanning electron microscopy and X-ray diffraction. A plastic deformation and particle detachment wear mechanism was revealed. Plasticity during sliding induced an austenite to martensite transformation. The presence of ceramic particles (Al₂O₃ and Y₂O₃) and sintering activators (B₂Cr, BN) improved significantly the wear resistance (especially the combination Al₂O₃ and B₂Cr). Ceramic particles limited plastic deformation while sintering activators decreased final porosity.     

Micro/nano-scale differential wear of multiphase materials: pole tip recession in magnetic-tape heads

Wear of multiphase materials at the micro/nano-scale is important in devices such as magnetic tape and disk drives, where the read-write heads are multiphase. Differential wear, which is caused by differences in wear resistance among the heads’ phases, causes the thin-film poles to recede from the bearing surface; this is called pole tip recession (PTR). It is a problem because it increases spacing between the poles and medium, resulting in lower readback amplitude. Here, PTR in tape heads is studied to understand micro/nano-scale differential wear. Test results suggest that three-body abrasion, which leads to primarily plastic wear, is the operative wear mode. Most of the three-body abrasive particles originate from the tape surface; the alumina head-cleaning agents (HCAs) in the tape, which function as load bearing particles at the interface, are believed to be the primary abrasives. Some of the particles originate from the head. These are important if the substrate material is relatively soft. Differential wear can be reduced by choosing a substrate that is harder than the tape’s HCAs, choosing a pole material that is as close as possible to the hardness of the substrate, and lowering the thickness of the head’s thin-film region. Material hardness matching will not reduce differential wear if a substrate is chosen that is less hard than the HCAs. An analytical model that accounts for the observed wear is presented. The model shows that each of the following leads to higher differential wear: increasing the thickness of three-body particles, increasing tension, decreasing thin-film hardness, and increasing the thin-film wear coefficient. An increase in thin-film wear coefficient can be caused by an increase in thin-film thickness or an increase in the number of particles at the interface.     

Effect of Particulate Contamination on Pole Tip Recession in a Linear Tape Drive

Three-body abrasion is the cause of differential wear in magnetic tape heads resulting in recession of the magnetic poles with respect to the head substrate; this is called pole tip recession (PTR). The increasing head--tape spacing caused by PTR results in a lower write density, so the recession must be minimized. The three-body particles that may interact with the head--tape interface can originate from the operating environment (contaminant particles) and from the interface itself (debris particles). The effect of airborne particulate contaminants trapped at the head--tape interface (particle concentration, size, and hardness), which results in three-body abrasion, on PTR growth is studied experimentally. PTR increases with increases in any of the following: particle concentration, size, and hardness. Analytical modeling supports the experimental results. Possible mechanisms responsible for the observed behavior are discussed.     

Chemical analysis of wear tracks on magnetic disks by TOF-SIMS

Surface reactions on magnetic recording disks have been studied during sliding with ceramic sliders in the main chamber of TOF-SIMS. Chemical change of lubricant oil in the wear track was observed by the chemical image of TOF-SIMS. The magnetic disk surface was covered with perfluoroalkyl polyether lubricant (Fomblin Zdol). The Si tip slider surface was covered with Al₂O₃, DLC, TiN or c-BN coating. Experimental conditions were as follows: 0.8 mN of load and a sliding speed of 0.01 m/s. Lubricant oils were decomposed with Al₂O₃ and TiN slider surfaces. Metal (Al, Ti) fluorides were detected by TOF-SIMS in the sliding track. Material transfer occurred by chemical wear of slider material. From TOF-SIMS observation, the decomposition of lubricant molecules was initiated at the end group of molecules (-CF₂CH₂OH). On the other hand, DLC and c-BN sliders suppressed the decomposition reaction of PFPE oils. In conclusion, hard and chemical inert materials such as DLC and c-BN are suitable for a long-life HDI.     

Comparison of wear behaviour of plasma-sprayed Al2O3 coatings with and without laser treatment

This paper studies experimentally the effects of CO₂ laser-treatment on the wear behaviour of plasma-sprayed Al₂O₃ coatings, in linear contact sliding (dry, abrasive and lubricated) against SAE 4620 steel. Tests were carried out using a block-on-ring friction and wear tester, under different loads at different speeds. The wear mechanism and the changes in adherence, porosity and microstructure by laser treatment were also investigated. Results show a better wear behaviour for both laser-treated ceramic coating and its paired steel under dry and abrasive conditions, compared with the case without laser treatment. The lubricated wear behaviour of the laser-treated ceramic coating, however, is not improved. The changes in microhardness, porosity and adherence caused by the laser treatment are responsible for the change in wear behaviour of the ceramic coating.     

Wear Behavior of (TiB2–TiC)–Ni/TiAl/Ti Gradient Materials Prepared by the FAPAS Process

(TiB₂–TiC)–Ni/TiAl/Ti functionally gradient materials were prepared by field-activated pressure-assisted synthesis processes. (TiB₂–TiC)–Ni composite ceramic, the top layer of the functional gradient materials, was prepared in situ by the combustion synthesis process using Ti and B₄C powders as raw materials. Scanning electron microscope (SEM) images of the ceramic layer revealed that the TiB₂ and TiC particles in the composite were fine and homogeneously dispersed in the Ni matrix. The friction and wear properties of the (TiB₂–TiC)–Ni ceramic were evaluated by sliding against a GCr15 disk at temperatures from ambient up to 400 °C. The experimental results showed that the friction coefficient of the (TiB₂–TiC)–Ni ceramic decreased with the increasing testing temperature, load, and sliding speed. However, the loss rate decreased at higher temperature and increased at higher load and higher sliding speed. The wear mechanisms of (TiB₂–TiC)–Ni ceramic mainly depend upon thermal oxidation at higher temperature, load, and sliding speed. The worn topography and phase component of the worn surfaces were analyzed using SEM, energy dispersive spectroscopy, and X-ray diffraction. The oxide films of Fe₂O₃, TiO₂, and B₂O₃ formed during the friction process play an important role in lubrication, which results in a smaller friction coefficient.     

Wear properties of two-phase Al2O3/ZrO2 (Y2O3) ceramics at temperatures from 296 to 1073 K

Reciprocating sliding friction experiments were conducted with various two-phase, directionally solidified Al₂O₃/ZrO₂ (Y₂O₃) pins sliding on B₄C flats in air at temperatures of 296, 873, and 1073 K under dry sliding conditions. Results indicate that all the Al₂O₃/ZrO₂ (Y₂O₃) ceramics, from highly Al₂O₃-rich to ZrO₂-rich, exceed the main wear criterion requirement of 10⁻⁶ mm³ N⁻¹ m⁻¹ or lower for effective wear-resistant applications. Particularly, the eutectics and Al₂O₃-rich ceramics showed superior wear properties. The composition and microstructure of Al₂O₃/ZrO₂ (Y₂O₃) ceramics played a dominant role in controlling the wear and friction properties. The controlling mechanism of the ceramic wear, friction, and hardness was an intrinsic effect involving the resistance to shear fracture of heterophase bonding and cohesive bonding and the interlocking microstructures at different scales in the ceramics.     

Wear of ceramic nozzles by dry sand blasting

Monolithic B₄C, Al₂O₃/(W,Ti)C and Al₂O₃/TiC/Mo/Ni ceramic composites, which provided a reasonably wide range of mechanical properties and microstructure, were produced to be used as nozzles materials. The erosion wear of the nozzle caused by abrasive particle impact was compared with dry sand blasting by determining the cumulative mass loss of the nozzles made from these materials. Results showed that the hardness of the nozzle material plays an important role with respect to its erosion wear. On the nozzle entry bore section, the B₄C nozzle appears to be entirely brittle in nature with the evidence of large scale-chipping, and exhibited a brittle fracture induced removal process. While the erosion mechanism of Al₂O₃/TiC/Mo/Ni nozzle appeared to be a preferential removal of the metal binder followed by pluck out of the undermined Al₂O₃ and TiC grains under the same test conditions. On the nozzle center bore zone, the B₄C nozzle fails in a highly brittle manner, and there are lots of obvious micro-cracks and small pits located on this area. While the primary wear mechanisms of Al₂O₃/TiC/Mo/Ni nozzle is plowing and micro-cutting by the abrasive particles. Both types of material removal model seem to be occurred for the Al₂O₃/(W,Ti)C nozzle.     

WEAR PERFORMANCE OF MULTILAYER-COATED CARBIDE TOOLS

Three multilayer-coated carbides [two trigon-shaped inserts: Ti(C,N)/TiC/Al₂O₃ (T1), Ti(C,N)/ Al₂O₃/TiN (T2) and one 80°-rhomboid shaped insert: TiC/Al₂O₃/TiN (T3)] were used to machine a martensitic stainless steel at various combinations of cutting speed and feed rate without coolant to assess their wear performance. Significant nose wear and chipping/fracture of the cutting edge were the predominant failure modes affecting tool performance at higher speed conditions. Plucking of tool materials was the main rake face wear phenomenon observed on T1 grade insert with alumina as the top-layer coating when machining at the lower speed conditions. Attrition and plastic flow were the main wear mechanisms observed on the ceramic coating layers, with dissolution-diffusion being the probable wear mechanism of the tool grades where tungsten carbide substrate had direct contact with the flowing chip. The fitted statistical wear models revealed T3 grade insert with 80°-rhomboid shape as having the highest speed-feed capability, resulting in the highest material removal rate relative to T1 and T2 grade inserts with trigon shapes.     

Cutting performance of Si<Subscript>3</Subscript>N<Subscript>4</Subscript>/TiC micro-nanocomposite ceramic tool in dry machining of hardened steel

A type of Si₃N₄/TiC micro-nanocomposite ceramic cutting tool material was fabricated using Si₃N₄ micro-matrix with Si₃N₄ and TiC nanoparticles. Cutting performance of the Si₃N₄/TiC ceramic cutting tool in dry cutting of hardened steel was investigated in comparison with a commercial Sialon insert. Hard turning experiments were carried out at three different cutting speeds, namely 97, 114, and 156 m/min. Feed rate (f) and depth of cut (a _p) were fixed at 0.1 mm/rev and 0.2 mm, respectively. Results showed that cutting temperature increased rapidly to nearly 1000 °C with increasing cutting speed. The two types of cutting tools featured similar wear behavior. However, the Si₃N₄/TiC micro-nanocomposite ceramic cutting tool exhibited better wear resistance than the Sialon tool. Morphologies of crater and flank wear were observed with a scanning electron microscope. Results indicated that wear variation of the two types of ceramic cutting tools differed in the same conditions. Wear of the Si₃N₄/TiC micro-nanocomposite ceramic cutting tool is mainly dominated by abrasion and adhesion, whereas that of the Sialon ceramic cutting tool is dominated by abrasion, adhesion, thermal shock cracking, and flaking.     

Wear behavior of some cutting tool materials in hard turning of HSS

This study presents an assessment of the performance of four cutting tool in the machining of medium hardened HSS: polycrystalline c-BN (c-BN+TiN), TiN coated polycrystalline c-BN (c-BN+TiN), ceramic mixed alumina (Al₂O₃+TiC), and coated tungsten carbide (TiN coated over a multilayer coating (TiC/TiCN/Al₂O₃)). The Al₂O₃+TiC and the coated carbide tools can outperform both types of c-BN at high cutting speeds. Raman and SEM mapping revealed an alumina tribo-layer that protects the surface of the Al₂O₃+TiC cutting tool. The high chemical and thermal stability of Al₂O₃ tribo-films protects the tool substrate because it prevents the heat generated at the tool/chip interface from entering the tool core.     

Sliding wear characteristics of plasma-sprayed Al2O3 and Cr2O3 coatings against copper alloy under severe conditions

Al₂O₃ and Cr₂O₃ coatings were deposited by atmospheric plasma spraying and their tribological properties dry sliding against copper alloy were evaluated using a block-on-ring configuration at room temperature. It was found that the wear resistance of Al₂O₃ coating was superior to that of the Cr₂O₃ coating under the conditions used in the present study. This mainly attributed to its better thermal conductivity of Al₂O₃ coating, which was considered to effectively facilitate the dissipation of tribological heat and alleviate the reduction of hardness due to the accumulated tribological heat. As for the Al₂O₃ coating, the wear mechanism was plastic deformation along with some micro-abrasion and fatigue-induced brittle fracture, while the failure of Cr₂O₃ coating was predominantly the crack propagation-induced detachment of transferred films and splats spallation.     

In situ formation of tribologically effective oxide interfaces in SiC‐based ceramics during dry oscillating sliding

The tribological behaviour of single‐phase SiC as well as both SiC–TiC and SiC–TiC–TiB₂ composite materials sliding against aluminium oxide has been investigated at room temperature with regard to the formation of wear‐reducing interfaces. The experiments were carried out in dry air for reasons of excluding the strong influence of water vapour. The introduction of the titanium phases into the SiC microstructure reduces the system wear by more than a factor of ten. The coefficient of friction is only slightly reduced but stabilised with time. The relatively abrasive oxide interface in the Al₂O₃/SiC pairing is altered to a soft and malleable oxide interface in the Al₂O₃/SiC–TiC–TiB₂ pairing. The wear reduction is mainly caused by a change of the wear mechanism so that the formed soft oxide wear debris is transferred to the counterbody, thus shifting the sliding plane further into the layer. This revised version was published online in July 2006 with corrections to the Cover Date.     

Wear of Ceramic Cutting Tools in Ni-Based Superalloy Machining

The machining performance of monolithic and composite silicon nitride and Al₂O₃-based cutting tools in continuous turning of Inconel 718 was examined. The character of tool wear has been found to vary, depending on the feed rate and cutting speeds. At a lower cutting speed, of 120 m/min, tool life is restricted by depth-of-cut notching, while at high cutting speeds (300 m/min), tools fail due to nose wear and fracture. The sensitivity of monolithic Si₃N₄ and Al₂O₃ to depth-of-cut notching was found to he significantly reduced with the addition of SiC whiskers, and to a lesser extent with TiC particulates. The ceramic composites also exhibited resistance to nose and flank wear that was higher than that of the monoliths. The internal stress distribution for the cutting tool has been calculated using the finite element method and is the basis for explaining fracture beneath the rake face. Cutting tool wear results are discussed in terms of chemical and mechanical properties of the ceramic tool material, abrasive wear, thermal shock resistance, and metal cutting conditions.