Friction and wear characteristics of organic thiophosphoro derivatives — a critical appraisal

The friction- and wear-reducing characteristics of a number of oil soluble sulphurised and phosphosulphurised derivatives for automotive and industrial applications have been reviewed. A critical appraisal of the suggested causes and mechanism of friction reduction and antiwear characteristics has been made. A review of the investigations carried out so far indicates that the creation of in situ films of simple inorganic salts, such as molybdenum disulphide, iron sulphide or phosphates of low shear strength and lamellar structures, does not appear to be the primary cause of low friction and wear. The authors have, therefore, undertaken a programme to synthesise and study the chemistry and tribochemical reactions in relation to friction and wear characteristics of hydrocarbon-soluble thiophosphoro derivatives of alkyl phenol, alcohols and fatty esters, in order to establish relationships between the reactivity, chemical nature and crystal structure of films formed on rubbing surfaces, and antifriction and antiwear characteristics. Molybdenum salts of various phosphorothio derivatives of pentadecylphenol and lauryl oleate of specific structures have been synthesised, and the friction and wear properties of their blends in mineral oil base stock have been studied. It can be clearly inferred from the results that type of bonding between sulphur, phosphorus and molybdenum, and reactivity of these derivatives with rubbing surfaces, determine their friction-reducing and antiwear characteristics. Their reactivity with iron and the nature of films formed are under investigation.     

The erosive wear behavior of basalt based glass and glass–ceramic coatings

In this study, the effects of impact angle and SiC reinforcement on the erosion wear behavior of basalt base glass and glass–ceramic coatings were investigated. Basalt powders with 0–50% SiC additions were coated on AISI 1040 steel by atmospheric plasma spray coating technique. Controlled heat treatment was applied to amorphous basalt base coatings for glass–ceramic transformation. Erosion tests were realized by using corundum media at the different impact angles and velocities. Wear test results showed that the SiC addition in the basalt based coatings resulted in increase erosive wear resistance of glass and glass–ceramic coatings.     

Effects of sliding velocity on tribo-oxides and wear behavior of Ti–6Al–4V alloy

Dry sliding wear tests were performed for Ti–6Al–4V alloy on a pin-on-disc wear tester. The wear behavior of Ti–6Al–4V alloy at sliding velocities of 0.5–4 m/s was studied and the tribo-oxides and their function were explored. Ti–6Al–4V alloy presented a marked variation of wear rate as a function of velocity. With the rise and fall of wear rate, Ti–6Al–4V alloy underwent the transitions of wear mechanisms from the combination of delamination wear and oxidative wear at lower speeds to delamination wear at 2.68 m/s, and then to oxidative wear at 4 m/s. These phenomena were attributed to the appearance and disappearance of tribo-oxides. In spite of trace or a small amount, tribo-oxides would change the wear behavior, and even wear mechanism.     

Experimental and numerical studies on metrological characteristics of swirlmeters with different swirler helix angles in a gas–solid two-phase flow

Swirlmeters are widely used to measure natural gas because of their simple structure, absence of internal moving parts and high measurement accuracy. However, fine particles in natural gas can affect swirlmeters’ metering accuracy. Hence, this study evaluated the metrological characteristics of swirlmeters measuring gas–solid two-phase flow with fine particles and different swirler helix angles. Experiments and simulations for swirlmeters with different solid–gas mass ratios and helix angles were performed. The results demonstrated that the swirlmeter meter factors decreased and pressure losses increased as the solid–gas mass ratio increased. With different solid–gas mass ratios, the most effective sensor detection position was at the throat outlet a half radius from the centre of the runner. The swirler with a smaller helix angle could significantly increase the meter factor, while the swirler with a larger helix angle could significantly decrease pressure losses. The swirlmeter internal flow losses were mainly derived from the swirler.     

Friction and wear of aluminium–steel contacts lubricated with ordered fluids-neutral and ionic liquid crystals as oil additives

Friction and wear of ASTM B211 aluminium–AISI 52100 steel contacts have been determined using pin-on-disk tests under variable conditions of normal applied load, sliding speed and temperature, in the presence of a lubricating base oil modified with a 1 wt.% proportion of three different liquid crystalline additives.The tribological behavior of the ionic liquid crystal n-dodecylammonium chloride (LC3) has been compared with that of two neutral liquid crystals: a non-polar species, 4,4′-dibutylazobenzene (LC1) which had previously shown its ability to lower friction and wear of metallic pairs as compared to the base oil, and a cholesterol derivative, cholesteryl linoleate (LC2).At low temperature and low sliding speed values, the friction coefficients obtained for LC1 are lower than those of LC3. As the severity of the contact conditions increases, this tendency reverses and the ionic species LC2 gives rise to lower friction values than LC1.Wear volume losses under increasing normal loads, between 2.45 and 5.89 N, are always lower in the presence of the ionic additive LC3.Lubrication and wear mechanisms are discussed from optical microscopy and SEM observation of the wear scars and wear debris morphology.     

Effect of active gas mixture composition on tribological behavior of coatings obtained by reactive magnetron sputtering of chromium in acetylene–nitrogen and acetylene–air gas mixtures

The tribological properties of chromium-based coatings deposited by reactive magnetron sputtering in argon–acetylene–nitrogen and argon–acetylene–air mixtures of different volume compositions have been studied. The coatings acquired in acetylene–nitrogen gas mixture have DLC structure and demonstrate high mechanical characteristics and low coefficient of friction values in dry friction. Although the coefficient of friction of these coatings has a tendency to decrease with the increasing nitrogen volume concentration in the mixture (until the values below 0.1 in dry friction in pair with silicon nitride), their performance diminishes at high contact pressures. This decrease was maximal for coatings deposited in acetylene–nitrogen gas mixture, with 80 vol % of nitrogen. The substitution of nitrogen with air is shown to considerably improve the performance, but a further increase in the air volume fraction above 85 vol % provokes a drastic decrease in the efficiency, especially at high contact pressures. The possible mechanisms of these effects and the abilities of their elimination are discussed, as well.     

Microstructures and abrasive wear performance of PTAW deposited Ni–WC overlays using different Ni-alloy chemistries

The microstructures and performance of Ni–WC (nickel–tungsten carbide) composite overlays deposited by plasma transferred arc welding are studied using a combination of microscopy, hardness, and wear testing. The Ni–WC overlays had microstructures consisting of γ-Ni dendrites, with interdendritic Ni-based eutectics, borides and carbides. Overlays which were produced with a low hardness Ni-alloy matrix contained a smaller fraction of interdendritic phases relative to the high hardness Ni-alloys.The dissolution of WC particles was observed following deposition of the MMCs, and this promoted the formation of secondary carbide phases. Ni-alloys with low carbon and low Cr content exhibited the least dissolution of WC. The Ni–WC overlays produced using these dilute alloys generally performed better in ASTM G65 wear tests. This was due to the increased fraction of retained WC phase, and the reduced fraction of brittle secondary carbide phases when the Ni-alloy contained no Cr.     

Role of Third Bodies in Friction and Wear of Cold-Sprayed Ti and Ti–TiC Composite Coatings

Titanium (Ti) and Ti-based alloy wear performance is often poor unless coating or lubricants are used. An alternative is to use hard phase reinforcement. Cold spray is a relatively new method to deposit composite coatings, where here we report the deposition of a Ti–TiC coating and its sliding wear behavior. Mixtures of mechanically blended Ti–TiC with various TiC content were injected into a de Laval nozzle and sprayed onto substrates. Two composite coatings and a pure Ti coating are reported here, where the as-sprayed compositions of the composites were 13.8 and 33.4 vol% TiC. Reciprocating dry sliding wear was performed using a custom-built in situ tribometer. All tests were conducted with a sliding speed of 3 mm/s and at a normal load of 0.5 N. Using a transparent sapphire hemisphere of 6.25 mm as counterface, dynamic behavior of third bodies was directly observed. It was found that adhesive transfer of Ti was the primary wear mechanism for the Ti coating, with oxidative and abrasive wear also occurring for longer sliding cycles. The superior wear resistance of the composite coatings compared to Ti was related to dual function of TiC particles, where they reinforced the Ti matrix and facilitated the formation of a stable and protective tribofilms. The tribofilms contained carbonaceous material that provided easier shear and lower friction. The formation of these tribofilms was highly dependent on the TiC particles, which contained excess carbon compared to the equilibrium composition. Higher TiC content was more effective in quickly developing and sustaining the tribofilms.     

Relations of counterface materials with stability of tribo-oxide layer and wear behavior of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si alloy

Dry sliding wear tests of Ti–6.5Al–3.5Mo–1.5Zr–0.3Si alloy (TC11 alloy) sliding against AISI 52100 and AISI M2 steels were performed under the load of 50–250 N at 25–600 °C. For two kinds of counterface materials, the titanium alloy presented totally different wear behaviours as the function of temperature. The appreciable variations of the titanium alloy sliding against different counterface materials were attributed the fact that a hard counterface caused unstable existence of tribo-layers by its microcutting action, thus resulting in the increase of wear rate. It is suggested that the hard counterface must be avoided as the counterface for the titanium alloy/steel sliding system.     

Frequency–spectrum characteristics of force in end milling with tool wear and eccentricity

The effects of chip load, tool wear, and tool eccentricity on milling force are similar; in order to distinguish them from each other, the spectral characteristics of milling force for four flute end mills was studied. With simplified milling force model, the calculation expression of instantaneous milling force under tool eccentricity was derived based on the 2D geometry of tool cutting into workpiece. Using simulation methods, the amplitude spectra of milling forces under neither wear nor eccentricity, only eccentricity, both wear and eccentricity, and the every phase spectrum of force caused only by wear of one tooth were analyzed. The analysis results showed that the basic and third harmonic amplitudes of spindle frequency were linear only with eccentric distance, the fourth harmonic amplitude was linear only with feed, the second harmonic component was in relationship only with tool wear, and harmonics with same frequency caused by wear of different teeth were in phase or out of phase. Then corresponding milling experiments were done, the relations between experimental harmonic amplitudes of force and milling parameters were analyzed, and were found being in good agreement with above simulation results. These indicate that amplitudes of these harmonics could be taken as indices in recognizing eccentricity, wear, and chip load, respectively, and their variations contain in-process information of tool wear. This study proposes a new idea of identifying tool eccentricity and wear with force itself.     

The Mathematical Simulation and Study of the Electrical Resistance of the Friction Zone of the Hip Joint Endoprosthesis with a Metal–Metal Friction Pair

The paper has described a model of the static load on the hip joint that takes into account the anthropological parameters and a mathematical model of the change in the resistance of the endoprosthesis under the influence of an external load at different rotation angles of the cup component. The theoretical studies have revealed the character of the changes and assessed the possible ranges of variations in the diagnostic parameter that are required to develop diagnostic equipment and methods for testing and interpreting diagnostic information during the tribotesting of individual types of implants.     

Hydrodynamic Friction Reduction in a MAC–Hexadecane Lubricated MEMS Contact

Recent research has shown that hydrodynamic lubrication is an effective means of reducing friction in high sliding micro-electromechanical systems (MEMS). At high speeds, however, such lubrication can lead to increased friction due to viscous drag. This article describes a series of hydrodynamic tests on a silicon MEMS contact lubricated with a blend of hexadecane and a multiply-alkylated cyclopentane (MAC). Results show that the presence of the MAC reduces hydrodynamic friction compared with neat hexadecane. Such behaviour is contrary to conventional hydrodynamic theory, since the viscosity of the MAC—a mixture of di- and tri-(2-octyldodecyl)-cyclopentane—is significantly higher than that of neat hexadecane. This effect increases with MAC concentration up to an optimum value of 3 wt%, where the hydrodynamic friction coefficient at 15,000 rpm is reduced from 0.5 to 0.3. Above this concentration, friction begins to rise due to the overriding effect of increasing viscosity. The viscosity of the blended lubricant increased monotonically with MAC concentration, when measured using both a Stabinger and an ultra-high shear viscometer. In addition to this, no reduction in friction was observed when a squalane–hexadecane blend of equal viscosity was tested. This suggests that some property of the MAC–hexadecane lubricant, other than its viscosity, is influencing hydrodynamic lubrication. A tentative explanation for this behaviour is that the MAC induces the liquid to slip, rather than shear, close to the silicon surfaces. This hypothesis is supported by the fact that the friction reducing ability of the MAC blend was inhibited by the inclusion of octadecylamine—a substance known to form films on silicon surfaces. Furthermore, the MAC reduces friction in the mixed regime, in a manner suggesting that the formation of a viscous boundary layer. This unusual behaviour may have useful implications for reducing hydrodynamic friction in liquid-lubricated MEMS devices.     

Tribo-layer and its role in dry sliding wear of Ti–6Al–4V alloy

Dry sliding wear tests were performed for Ti–6Al–4V alloy under a load of 50–250 N at 25–500 °C on a pin-on-disk elevated temperature tester. Worn surfaces and subsurfaces were thoroughly investigated for the morphology, composition and structure of tribo-layers. Ti–6Al–4V alloy could not be considered to possess poor wear resistance at all times, and presented a substantially higher wear resistance at 400–500 °C than at 25–200 °C. The tribo-layer, a mechanical mixing layer, was noticed to exist on worn surfaces under various conditions. High wear rate at 25–200 °C was ascribed to no protective tribo-layer containing no or trace tribo-oxides. As more oxides appeared in the tribo-layers, they presented an obviously protective role due to their high hardness, thus giving a reasonable explanation for high wear resistance of Ti–6Al–4V alloy at 400–500 °C.     

Friction and wear behaviour of plasma sprayed WC–12Co coating sliding against Si3N4 under lubrication of ionic liquids

Abstract

The friction and wear behaviour of a WC–12Co coating prepared by plasma spraying sliding against a Si₃N₄ ceramic ball, under the lubrication of liquid paraffin and ionic liquids 1-methyl-3-butylimidazolium hexafluorophosphate and 1-methyl-3-hexylimidazolium hexafluorophosphate at room temperature, was investigated using an SRV tester. The morphology and elemental distribution of the worn coating surfaces were characterised by means of scanning electron microscopy (SEM) equipped with an energy dispersive X-ray analyser (EDXA) attachment, and the chemical state of typical elements in the boundary lubricating film on the worn coating surface was analysed by means of X-ray photoelectron spectroscopy (XPS). The SEM/EDXA analysis shows that phosphorus is uniformly distributed on the worn coating surface lubricated by ionic liquids. The XPS results also indicate that the boundary lubricating film is mainly composed of CoF₂ and PF_x and the tribochemical reaction products contribute to reducing the friction and wear of the plasma sprayed WC–12Co coating.     

Numerical simulation of sliding wear for a polymer–polymer sliding contact in an automotive application

Injection moulded polymer-based components are important for cost effective and fast production/assembly of auxiliary mechanisms in automotive industry. Wear is one of the critical factors, which influences the reliability and useful life in such mechanical components. Experimental determination of life parameters in terms of wear has both a cost and time impact. Therefore, the ability to predict wear at the development stage enables the designers to come up with a better design, longer useful life and more reliable products. This paper presents a numerical simulation of wear for a polymer–polymer sliding surface contact in dry conditions. Finite element analysis (FEA) is used as a tool to calculate nodal pressures at the contact area for small sliding steps. These pressures are then inputted to a customized wear calculating routine. The routine uses averaged wear coefficients (wear rates) obtained from custom designed experiments. The FE contact geometry is modified after each sliding step to account for the contact height decay thus determining wear volume loss over usage time and predicting the worn geometry.     

Sliding wear of 100Cr6 in a diesel-lubricated flat–flat contact under realistic loads

The tribological limits of martensitic AISI 52100 steel were determined by the application of a wear-mapping technique based on the statistical design of experiments. Wear measurements were conducted on a pin-on-disc system lubricated with a low-lubricity diesel fuel, with both pin and disc constructed of the same AISI 52100 steel. The test bench was equipped with a displacement transducer and an accurate temperature control of the samples temperature, enabling low wear rates to be measured in situ by the displacement transducer without being perturbed by thermal dilatation. By this method it is possible to measure wear rates on the order of a few nm/h. Moreover, the wear of the disc was evaluated at the end of each test by profilometry. A statistical model was fitted to the obtained results. Combining the findings of several surface characterisation methods, we identified two active wear mechanisms: tribocorrosion at low contact pressures (15 N/mm²) and adhesive wear at higher loads. This conclusion was corroborated by examinations of wear particles carried out by scanning electron microscopy and transmission electron microscopy.     

Influence of rigid and frictional kinematic linkages in tool–workpiece contact on the uniformity of tool wear

The motion of the machined part over the tool’s working surface is considered in raster finishing with frictional kinematic linkage. The relative trajectories of the part and tool are analyzed. In forward movement of the lap, rigid kinematic linkage in the part–tool contact is recommended.     

The Influence of Surface Modification on Friction and Lubrication Mechanism Under a Bovine Serum–Lubricated Condition

Diamond-like carbon (DLC) and microdimples are two potential surface modification techniques that are extensively studied to be utilized in biotribological interfaces in order to reduce the friction coefficient and wear rate. However, in situ observation of bovine serum–lubricated DLC and microdimpled surface contacts are not well understood. In this study, a DLC-coated and a microdimpled steel ball rubbing against a Cr-coated glass disk, where 25% bovine serum was used as a lubricant and the temperature was maintained at 37°C, were investigated. The behaviors of ithe nterface were ca`ptured using optical interferometry and the friction coefficients were simultaneously measured using a torque sensor. The experimental results reveal that DLC/glass sliding is scuffing-free, with a lower friction coefficient; however, the formation of a lubricating film is insignificant. On the other hand, the dimples retained lubrication and, as a result, the wear of the glass disk was minimized; however, the friction coefficient was not reduced. Therefore, DLC and microdimples individually have few improved tribological features, but their combination should be considered to maximize performance.     

Influence of graphite content on the dry sliding and oil impregnated sliding wear behavior of Al 2024–graphite composites produced by in situ powder metallurgy method

The influence of graphite content on the dry sliding and oil impregnated sliding wear characteristics of sintered aluminum 2024 alloy–graphite (Al/Gr) composite materials has been assessed using a pin-on-disc wear test. The composites with 5–20 wt.% flake graphite particles were processed by in situ powder metallurgy technique. For comparison, compacts of the base alloy were made under the same consolidation processing applied for Al/Gr composites. The hardness of the sintered materials was measured using Brinell hardness tester and their bending strength was measured by three-point bending tests. Scanning electron microscopy (SEM) was used to analyze the debris, wear surfaces and fracture surfaces of samples. It was found that an increase in graphite content reduced the coefficient of friction for both dry and oil impregnated sliding, but this effect was more pronounced in dry sliding. Hardness and fracture toughness of composites decreased with increasing graphite content. In dry sliding, a marked transition from mild to severe wear was identified for the base alloy and composites. The transition load increased with graphite content due to the increased amount of released graphite detected on the wear surfaces. The wear rates for both dry and oil impregnated sliding were dependent upon graphite content in the alloy. In both cases, Al/Gr composites containing 5 wt.% graphite exhibited superior wear properties over the base alloy, whereas at higher graphite addition levels a complete reversal in the wear behavior was observed. The wear rate of the oil impregnated Al/Gr composites containing 10 wt.% or more graphite particles were higher than that of the base alloy. These observations were rationalized in terms of the graphite content in the Al/Gr composites which resulted in the variations of the mechanical properties together with formation and retention of the solid lubricating film on the dry and/or oil impregnated sliding surfaces.