Effect of load,area of contact and contact stress on the wear mechanisms of a bonded solid lubricant film

A pin-on-disk type of friction and wear apparatus was used to study the effect of load, contact stress and rider area of contact on the friction and wear properties of polyimide-bonded graphite fluoride films. Different rider area contacts were obtained by initially generating flats (with areas of 0.0035,0.0071, 0.0145 and 0.0240 cm²) on 0.476 cm radius hemispherically tipped riders. Different projected contact stresses were obtained by applying loads of 2.5–58.8 N to the flats. Two film wear mechanisms were observed. The first was found to be a linear function of contact stress and was independent of rider area of contact. The second was found to increase exponentially as the stress increased. The second also appeared to be a function of rider contact area. Wear equations for each mechanism were empirically derived from the experimental data. In general, friction coefficients increased with increasing rider contact area and with sliding duration. This was related to the build-up of thick rider transfer films.     

The effect of abrasive grain size on the transition between abrasive and adhesive wear

Experiments were carried out in which SiC abrasives with a grain size range of 3–150 μm were inserted between sliding metals. The metals were pure aluminium, copper, iron, nickel and zinc. The test geometry was a tube end against a flat surface. The effect of grain size can be classified into three regimes. In the first, where abrasive grains are larger than a critical size d_c (about 50 μm), the wear rate is independent of grain size. In the second regime the wear rate decreases as abrasive grains become smaller than d_c to a limit at a transition grain size d_t (about 10 μm). In the third regime the wear rate is high and independent of abrasive grain size. The wear debris consists of large metal flakes with abrasive particles mixed in. Although abrasive particles are present, the wear is primarily adhesive, and the action of the abrasive particles is to promote the removal of metallic wear debris from the contact region.     

Wear,Friction, and Electrical Noise Phenomena in Severe Sliding Systems

The sliding mechanisms of unlubricated gold and palladium are described. Transfer, roughening, wear, friction, and contact resistance phenomena involve the same discrete events.

With rider-flat geometry, severely Worked transfer particles form a prow-shaped wedge which adheres to the smaller member. Even when rider and flat are different, prow material comes from the larger part. Loss of prow occurs by adhesive weld-back transfer and, to form loose debris, by shearing or fatigue fracture.

Friction rises in the early stages of sliding as prows grow. Soon, back transfer increases hardness of the larger member and friction falls to an equilibrium level. Friction also falls when prows are kneaded into rollers and become loose debris. During these stages, wear rate diminishes.

Contact resistance noise originates in stick-slip, roller formation, surface hardening, and changing composition at the sliding interface when dissimilar contact metals are involved.     

The sliding wear of 316 stainless steel in air in the temperature range 20–500°C

The friction and reciprocating wear of 316 stainless steel in air has been investigated in the temperature range 20–500°C at constant load using a standard pin and flat geometry. A marked change in wear behaviour occurred above 300°C. From room temperature to 300°C the wear rate decreased slowly with increasing temperature. This was accompanied by an increasing fraction of oxide in the wear debris. At 300°C the debris consisted entirely of oxide with the α Fe₂ O₃ structure. In this temperature range wear can be explained essentially in terms of mild wear. Above 300°C the wear rate decreased by an order of magnitude and was accompanied by a severely distorted wear surface. There was a high proportion of metallic particles in the wear debris. The surface roughening occurs at an early stage of wear and stops when glazed oxide regions form. The low wear rate is explained in terms of the high hardness of the glazed load-bearing areas and re-incorporation of wear debris into the wear scar.     

A chemical study of wear particles and other features associated with the wear of ceramics

A sapphire convex surface was loaded against a reciprocating flat SiC counterface material. In this particular study the chemical nature of the wear surfaces and associated features such as the wear debris and local areas of material transfer have been studied using analytical techniques such as EDX, XPS and AES. Prior to wear tests the SiC substrate is covered with a thin (1–2 nm) layer of SiO₂. During wear the thickness of this layer is substantially reduced, and wear debris of a cylindrical morphology is produced. Examination of the outer 1–2 μm of the wear debris, as well as the first few atomic layers, by EDX and AES, respectively, showed very similar results in areas rich in oxygen accompanied by varying quantities of Al and Si but litte carbon. It is proposed that the wear debris is initially produced by the fragmentation of asperities on the two wear surfaces followed by the transfer of a wear film of SiO₂. Such equiaxed debris is then agglomerated into a characteristic cylindrical particle that lies normal to the reciprocating motion.     

Friction at Small Displacement

Low contact resistance between metal surfaces is often observed in spite of interposed lubricant and/or oxide films. To study this effect an apparatus is used with which normal force and tangential microdisplacement are applied between a small lead rider and a gold flat with various surface film conditions. Simultaneous oscillograph records are made of forces, displacement, and contact resistance. A unique low compliance force transducer allows direct recording of the frictional behavior during microdisplacement.

Under nonoxidized and nonlubricated conditions, and with either oxide or stearic acid lubricant film alone, friction is high and contact resistance is low. With oxide and lubricant together, friction is much lower and slide is smooth, but contact resistance remains low and Ohm's law is obeyed.

The results are consistent with Greenwood's theory of contact resistance for a cluster of minute metallic contact spots within the load-supporting area. The contact resistance of such a cluster is indistinguishable, for practical purposes, from that given by complete metallic contact.     

Tribological Behavior of Composites Based on ZA-27 Alloy Reinforced with Graphite Particles

The objective of this investigation is to assess the influence of graphite reinforcement on tribological behavior of ZA-27 alloy. The composite with 2 wt% of graphite particles was produced by the compocasting procedure. Tribological properties of unreinforced alloy and composite were studied, using block-on-disk tribometer, under dry and lubricated sliding conditions at different specific loads and sliding speeds. The worn surfaces of the samples were examined by the scanning electron microscopy (SEM). The obtained results revealed that ZA-27/graphite composite specimens exhibited significantly lower wear rate and coefficient of friction than the matrix alloy specimens in all the combinations of applied loads (F _n ) and sliding speeds (v) in dry and lubricated tests. The positive tribological effects of graphite reinforcement of ZA-27 in dry sliding tests were provided by the tribo-induced graphite film on the contact surface of composite. In test conditions, characterized by the small graphite content and modest sliding speeds and applied loads, nonuniform tribo-induced graphite films were formed leading to the increase of the friction coefficient and wear rate, with increase of the sliding speed and applied load. In conditions of lubricated sliding, the very fine graphite particles formed in the contact interface mix with the lubricating oil forming the emulsion with improved tribological characteristics. Smeared graphite decreased the negative influence of F _n on tribological response of composites, what is manifested by the mild regime of the boundary lubrication, as well as by realization of the mixed lubrication at lower values of the v/F _n ratio, with respect to the matrix alloy.     

Reciprocating friction and wear behavior of Ti3AlC2 and Ti3AlC2/Al2O3 composites against AISI52100 bearing steel

In this work, the dry sliding friction and wear properties of Ti₃AlC₂ and Ti₃AlC₂/Al₂O₃ composites against AISI52100 steel ball were investigated using a reciprocating ball on flat configuration under different normal loads. The results indicated that the friction/wear processes of both Ti₃AlC₂ and the composites against AISI52100 steel experienced two different stages with an abrupt transition between them under all test conditions. The first stage was characterized by low coefficient of friction (μ) and neglectable wear rate. While the second stage was of much higher wear rate and μ. When the transition occurred, μ increased dramatically accompanied with formation of a mass of debris. In Ti₃AlC₂, the main wear mechanisms during the first stage involved surface materials transfer and oxidation accompanied with subsurface damages by grains kinking, delamination as well as transgranular and intergranular cracks. Accumulating of such contact damages under repeated sliding contact finally leaded to surface and subsurface microfracture of Ti₃AlC₂. Then microfracture controlled severe wear started. Incorporation of Al₂O₃ in Ti₃AlC₂ not only improved wear resistance of Ti₃AlC₂ but also extended the first mild friction/wear stage, because Al₂O₃ particles borne load and restrained large-scale deformation and microfracture of Ti₃AlC_2.     

The effect of cast iron graphite on friction and wear performance III: The lubricating effect of graphite under rolling-sliding contacts

The formation of nodular cast iron graphite films and the factors affecting squeeze film formation during rolling-sliding contact are discussed. The lubricating effect of the graphite is confirmed by roller tests and by practical gear tests. The frictional torque behaviour and wear change with surface treatments such as etching and hardening. The wear loss of ground specimens is greater than that of etched specimens because of differences in the substrate hardness and the microstructure. The formation of cast iron graphite films on hardened ground surfaces covered with a plastic flowed layer is difficult because of the small plastic deformation of the substrate, and severe wear occurs. The lowest values of the frictional torque and of the wear rate are obtained for ground surfaces with a substrate hardness of about 300 HV. This is due to the ease of formation of a graphite film as a result of the combined effects of fatigue failure of the surface and a squeeze phenomenon. The size of the spherical graphite particles affects film formation. If the size is doubled, the wear rate is halved. The grinding of tooth surfaces has a detrimental effect on the fatigue wear life.     

Effect of the Synergetic Action on Tribological Characteristics of Ni-Based Composites Containing Multiple-Lubricants

Ni-based self-lubricating composites with multiple-lubricants addition were prepared by a powder metallurgy technique, and the effect of multiple-lubricants on tribological properties was investigated from room temperature to 700?°C. The synergetic effects of graphite, MoS₂, and metallic silver lubricants on the tribological characteristics of composites were analyzed. XRD analysis showed that new Cr _x S _y and Mo₂C phase were formed in the composites containing graphite, MoS₂ and metallic Ag lubricants during the sintering process. The average friction coefficients (0.69?C0.22) and wear rates (11.90?C0.09?×?10^?5?mm³?N^?1?m^?1) were obtained when rubbing against Inconel 718 alloy from room temperature to 700?°C due to synergetic lubricating action of multiple-lubricants. A smooth lubricating was gradually generated on the worn surface, and the improving of tribological properties was attributed to the formation of lubricious glaze film on the worn surface and their partially transferred to the counterface. The graphite played the main role of lubrication at room temperature, while molybdate phase and graphite were responsible for low friction coefficients and wear rates at mid/high temperatures. The synergetic lubricating effect of molybdate (produced in the rubbing process at high temperatures) iron oxide (transfer from disk material to the pin) and remaining graphite multiple-lubricants play an important lubricating role during friction tests at a wide temperature range.     

Review of oxidational wear: Part I: The origins of oxidational wear

This is the first part of a two-part in-depth review of the oxidational wear of metals. It discusses the parallelism between the formation of an oxide film for dry contact conditions and of other surface films for lubricated contacct. Wear modes are unified into two major classes of mild and severe wear, including both lubricated both dry and conditions. Oxidational wear is a mechanism of mild wear in which protective oxide films are formed at the real areas of contact (during the time of a contact) at the contact temperature, T_cc. When the oxide reaches a critical thickness ξ, usually 1 to 3 μm, the oxide breaks up and eventually appears as wear particles. These oxides are preferentially formed on plateaux, which alternately carry the load - as they reach their critical thickness - and are removed. Temperature is important in determining the structure of the oxide film present, which in turn affects the wear properties of the sliding interfaces. Hence, this part of the review concludes with a thorough treatment of the thermal aspects involved during the sliding of a typical laboratory simulation of the oxidational wear of steel specimens without lubrication. This treatment shows how the general surface temperature (T_s) and the division of heat (?)_at the interface can be calculated and used, in conjunction with the measured wear rate (w), to give information about a possible surface model consisting of N contracts on the (thermally expanded) operative plateau, the height of the plateau being identical to the critical oxide film thickness (ξ) mentioned above.Part II outlines recent research to determine the oxidational constant, ie the activation energy and the Arrhenius constant, relevant to oxidational wear. It is found that the Arrhenius constant for oxidational wear is different from that for static oxidation tests. Some typical values of N, ξ and T_c are calculated from oxidational wear experiments. A new oxidational wear theory designed to take into account the oxide growth which occurs at the general surface temperature, T_s (where T_s < T_c) , whilst operation plateau is out-of-contact. This theory is most relevant to weat at elevated temperatures, where it is not permissible to assume that out-of-contact oxidation is negligible. After a brief review of the small amount of work done on the effects of partial oxygen pressures on oxidational wear, Part II concludes with a discussion of the possible connection between the general oxidational wear theory for dry contacts and the wear which occurs at lubricated contacts.     

The Development and Use of Thin Film Thermocouples for Contact Temperature Measurement

A procedure was developed for producing thin film thermocouples (TFTC) on the contact surface of sliding mechanical components. The thermocouple devices were made from thin films of vapor-deposited copper and nickel. The measuring junctions of the thermocouples were approximately 2 μm thick and between 80 μm and 300 μm across. The TFTC devices were found to have extremely rapid (< 1 μS) response to a sudden temperature change and did not significantly disturb the heat flow from the sliding contact. It was found necessary to sandwich the TFTC between thin films of a hard, non-conducting ceramic (Al₂O₃ in the current work) to insulate the thermocouple electrically from the substrate and protect it during sliding.

Thin film thermocouple devices were applied to the measurement of sliding surface temperatures in two cases, oscillatory dry sliding of a polymer pin on a flat surface, and uni-directional dry sliding of a ring over a flat pin surface. Results from the tests verified theoretical predictions.     

Tribological Properties of Langmuir–Blodgett Films on Silicon Surface in Microscale Sliding Contact

Microtribological properties of Langmuir–Blodgett (LB) films transferred from behenic acid (BehA), 2,4-heneicosanedione (HD) and its copper complex ((HD)₂Cu) onto silicon surface were examined. To better understand the wear resistance performance of these LB monolayers, a comparison was made with a chemically grafted octadecyltrichlorosilane (OTS) monolayer. Auger electron spectroscopy (AES) was used for identification of the chemical composition of the monolayers, worn areas and counterpart surfaces. We observed that the studied LB films in microscale sliding contact exhibited stable friction properties comparable to OTS, and better wear performance than OTS at high contact pressure. The tribological properties of these LB monolayers were explained in terms of molecular packing density and molecular transfer to the counterpart surface. The relationship between the wear resistance of the studied LB films and the degree of molecular packing of the surfactants indicated that the wear properties of the LB films are strongly associated with the degree of molecular packing. We suggest that the steady low friction and high wear resistance of the BehA monolayer may partly be attributed to the transfer of the amphiphilic molecules to the counterpart surface in the contact region.     

Stages in the Wear of a Prow-Forming Metal

The stages in wear of a typical prow-forming metal, gold, were determined. They are: 1) prow formation at the initiation of sliding, characterized by a high wear rate, limited to the member having the larger surface involved in sliding (i.e., the flat in a rider-flat apparatus); 2) an intermediate stage of roughening and work hardening of the flat with reduction in its wear rate; and 3) a transition stage to the rider wear process. Soon after the transition, the flat gains mass, and the rider loses metal by transfer to the flat or as loose debris. The combined wear of both members for a given total sliding distance lessens with decreasing track length for unidirectional and reciprocating sliding—-both before and after the transition. Also, the number of passes to the transition is proportional to the length of track divided by the load. These phenomena originate in an increasing ratio of transfer to wear with decreasing track length, due to a diminished ability of wear debris to leave the zone of sliding. This increases the rate at which the track achieves the critical roughness and worked condition necessary for the transition.     

Combined influences of mechanical properties and surface roughness on the tribological properties of amorphous carbon coatings

Carbon films (∼2 μm thick) with a range of mechanical properties and underlying substrate roughnesses were evaluated for delamination and wear under conditions of combined impact and sliding contact. One-side-coated and both-sides-coated titanium alloy pin and disk wear couples were assessed using a custom-made impact/sliding pin-on-disk apparatus in a colloid-based blood volume expansion medium. The normal stress distribution along the film/substrate interface upon impact loading by a smooth titanium alloy pin was modelled analytically for each coated system. For disk surface roughness centre-line average (R_a) values below 0.05 μm, the area of disk film delamination was shown to correlate with the presence of tensile stress at the film/substrate interface. The interfacial tensile stress was shown to occur when there was a film/substrate elastic modulus mismatch, either within or outside the perimeter of contact, depending on the direction of the film modulus deviation. We propose that the tensile stress promotes delamination by lifting the film locally from the substrate. With increased disk R_a, the area of disk coating loss tended to decrease, because the surface roughness improved the mechanical bonding of the composite system.     

Study on the tribological behaviors of the phenolic composite coating filled with modified nano-TiO2

In order to overcome the disadvantages generated by the loosened nanoparticle agglomerates dispersed in polymer composite coatings, nano-TiO₂ particles are modified using trifluoracetic acid. The friction and wear properties of the phenolic coatings filled with different surface treated nano-TiO₂, sliding against AISI-C-52100 steel ring under dry sliding, were investigated on a MHK-500 wear tester. Owing to the effective improvement of their dispersibility in the phenolic coating, compared with the cases of untreated nano-TiO₂, the employment of modified nano-TiO₂ provided the phenolic coating with much better tribological performance. Worn surfaces of the untreated nano-TiO₂ or modified nano-TiO₂ filled phenolic coating and transfer films formed on the surface of the counterpart ring sliding against the composite coating were respectively investigated by SEM and optical microscope (OM), from which it is assumed that the optimal content of TiO₂ or TF-TiO₂ is able to enhance the adhesion of the transfer films to the surface of counterpart ring. As a result, the wear resistance of the phenolic composite coating filled with modified nano-TiO₂ was significantly enhanced, especially at extreme wear conditions, i.e. high contact pressures.     

Influence of Deposition Positions on Fretting Behaviors of DLC Coating on Ti-6Al-4V

Abstract

The influence of diamond-like carbon (DLC) coating positions—coated flat, coated cylinder, and self-mated coated surface tribopairs—on the fretting behaviors of Ti-6Al-4V were investigated using a fretting wear test rig with a cylinder-on-flat contact. The results indicated that, for tests without coating (Ti-6Al-4V–Ti-6Al-4V contact), the friction (Q_max/P) was high (0.8–1.2), wear volumes were large (0.08–0.1?mm³) under a large displacement amplitude of ±40 µm and small (close to 0) under a small displacement amplitude of ±20 µm, and the wear debris was composed of Ti-6Al-4V flakes and oxidized particles. For tests with the DLC coating, under low load conditions, the DLC coating was not removed or was only partially removed, Q_max/P was low (≤0.2), and the wear volumes were small. Under high load conditions, the coating was entirely removed, Q_max/P was high (0.6–0.8), and the wear volumes were similar to those in tests without coating. The wear debris was composed of DLC particles, Ti-6Al-4V flakes, and oxidized particles. The DLC coating was damaged more severely when deposited on a flat surface than when deposited on a cylindrical surface. The DLC coating was damaged more severely when sliding against a DLC-coated countersurface than when sliding against the Ti-6Al-4V alloy.     

Subsurface damage during dry sliding wear of Al-Al3Ni eutectic alloy

Cylindrical Al-Al₃Ni eutectic alloy wear pins (10 mm in diameter) were slid against a polished steel surface in a pin-on-disc rotating machine under unlubricated conditions with bearing pressures of 6–60 kPa and a constant sliding speed of 70 m min^?1. Metallographic changes in the subsurface region of contact were examined by optical microscopy and microhardness measurements. In the bearing pressure range investigated the alloy exhibited “mild” wear in two linear regions identified as pure “oxidative” wear at low bearing pressures and oxidative with superimposed “metallic” wear at higher bearing pressures. Plastic deformation and fragmentation of the Al₃Ni phase occurred under all bearing pressures. However, in composites prepared by unidirectional solidification containing large Al₃Ni particles fragmentation was insignificant. In all other specimens the size of the fragmented particles in the subsurface region of contact was about 5 μm irrespective of the bearing pressure.     

A metallographic examination of rollers subjected to wear under rolling-sliding conditions

Wear rate versus maximum contact pressure p₀ curves were obtained at 3%, 6% and 9% creep for rollers of a fracture tough rail steel (0.40 C-1.46 Mn) that were tested in a twin-disc wear and lubrication machine. Subsurface cracks were observed to form below and above the mild-severe wear transition; these increased in depth and profusion with increasing creep and increasing p₀. Cracks close to the surface are almost parallel with it and eventually break through to form flake-like particles of wear debris. Undeformed inclusions or inclusions with a low index of deformation are considered to be crack initiators, and Al₂O₃ particles were mainly associated with the cracks although more malleable MnS was also found. Tangential contact forces obtained from positive creep and an adequate coefficient of friction are necessary for crack formation. Microhardness tests disclosed that the wear rate appears to correlate with hardness at the extreme surface.     

Tribological properties of anatase TiO<Subscript>2</Subscript> sol–gel films controlled by mutually soluble dopants

Tribological properties of TiO2 sol–gel thin films with mutually soluble dopants were studied on a glass substrate. The results showed that the formation of mutually soluble solid solution played a very important role in the growth of titania grains. The fine-grained TiO₂ films controlled by SiO₂ dopant were superior to pure TiO₂ film in wear resistance and endurance life, although both films greatly improve the surface characteristics of glass substrate, enhancing its tribological characteristics. High resistance to microfracture because of the very small grain size as well as a good adhesion of the film to the substrate is believed to be the determining factors influencing the tribological properties of SiO₂ doped TiO₂ films. However, excessive SiO₂ seriously deteriorates wear resistance of film due to phase separation. The wear mechanisms were also discussed based on the observation of the surface morphologies by scanning electron microscope (SEM).