Tribological Behavior of TiC/a-C:H-Coated and Uncoated Steels Sliding Against Phenol–Formaldehyde Composite Reinforced with PTFE and Glass Fibers

Tribological experiments on phenol–formaldehyde composite reinforced with polytetrafluoroethylene (PTFE) and glass fibers were performed against 100Cr6 steel and TiC/a-C:H thin film-coated 100Cr6 steel. In both cases, the coefficient of friction increases with increasing sliding distance until a steady-state value is reached. Although the steady-state values of the coefficient of friction are very close and ultralow, the wear rate of the PTFE composite liner at a long sliding distance (1,000 m) is reduced when the steel ball is coated with the TiC/a-C:H coating. This behavior is mainly attributed to the smoother surface after long sliding and the improved wear resistance of TiC/a-C:H coating. PTFE transfer films are evident on the surfaces of the hard counterparts. The average thickness of the transfer film on TiC/a-C:H-coated surfaces is about 3.8 nm. On the surface of uncoated steel ball, a continuous but non-uniform transfer film of around 13.9 nm average thickness was found.     

Tribological behavior of plasma-enhanced CVD a-C:H films. Part I: effect of processing parameters

A systematic study was conducted on the effect of plasma-enhanced CVD processing parameters, namely bias voltage, pressure and CH₄/Ar flow ratio, on the characteristics and tribological response of amorphous hydrogenated carbon (a-C:H) films. Film hardness, intrinsic stress, structure, composition and tribological response were characterized. Variation of processing parameters was found to produce a-C:H films with a range of characteristics with the CH₄/Ar ratio exercising a dominant effect. A low ratio produced harder films with more sp³ bonding, low hydrogen content and low wear rate; whereas a high ratio produced softer films, with more sp² bonding, higher hydrogen content and low friction. Film characteristics were found to affect the wear mechanism with softer films showing a layer-by-layer removal and harder films involving formation of fine debris. These two diverse types of films offer the opportunity to synthesize multilayered films combining desirable properties from each component.     

Tribochemical effects on the friction and wear behaviors of a-C:H and a-C films in different environment

Friction and wear behaviors of hydrogenated amorphous carbon (a-C:H) and hydrogen-free amorphous carbon (a-C) films sliding against Si₃N₄ balls were investigated in different testing environments. The result showed that two films with extreme chemical disparity (one hydrogenated, and the other hydrogen free) showed distinct different friction and wear behaviors, and the friction and wear behaviors of the both films were strongly dependent on the environment. For a-C:H films, much low friction coefficient and wear rate were obtain in dry N₂. In the water and/or oxygen containing environments, the friction coefficient and wear rate of a-C:H films were obviously increased. On the contrary, a-C films only provided low friction coefficient and wear rate in the presence of water and/or oxygen in the test chamber. In dry N₂, the highest friction coefficient and wear rate were observed for a-C films. By investigating the worn surfaces of the films using XPS, it was proposed that the environment dependence of the friction and wear behaviors of the films was closely related with the friction-induced chemical interactions between the films and water and/or oxygen molecules. The specific roles of hydrogen, water and oxygen molecules and their tribochemical effects on the friction and wear mechanism of the films are discussed.     

Structure and tribological behavior of nanocomposite C-Ti-WSe x coatings

Nanocomposite thin C-Ti-WSe _x coatings, which contain antifriction (WSe _x and amorphous carbon a-C) and hard (β-WC and TiC) components, are produced by pulsed laser deposition. In order to improve the tribological characteristics of the WSe _x phase and to transform the structural state of the a-C matrix, alloying with titanium is used. The characteristics of the coatings are determined using the sliding of a steel ball at an increased humidity. A comparison of the characteristics of a composite C-Ti-WSe _x coating and a carbon coating alloyed with titanium (a-C(Ti)) shows that the modification of the a-C matrix by introducing the WSe _x phase leads to an increase in the coefficient of friction from 0.05 to 0.2; the wear of the composite coating is approximately six times higher than that of the a-C(Ti) coating. Possible solutions for improving the tribological characteristics of the composite C-Ti-WSe _x coating in humid air are considered.     

Wear Resistance of Fine-Grained High Nitrogen Austenitic Stainless Steel Coated with Amorphous Carbon Films: The Soft X-ray Spectroscopy Approach

The wear resistance dependence on grain size of a high-nitrogen-alloyed austenitic stainless steels (HN) is investigated and compared to measurements for the same samples coated with amorphous carbon (a-C:H) and nitrogenated amorphous carbon (a-C:H(N)) films, deposited by means of plasma-enhanced chemical vapour deposition. A synergic effect between the grain refining and the film in the case of nitride amorphous carbon overcoats is observed in terms of increased low-friction performance duration. The temperature dependence of the wear resistance of a micro crystalline HN stainless steel coated with carbon films is also investigated. An overall decrease of the films' wear resistance is found with increasing temperature. Furthermore, a higher wear resistance is found in the a-C:H coated steel with respect to the a-C:H:N material. High-lateral-resolution photoemission microscopy reveals that inhomogeneities within the film after wear testing are correlated to an increase of the number of N-sp² C-bonded sites. The study of energy-distribution curves and high-lateral-resolution images on the nitrogenated samples shows that a modification of the surface chemistry occurs by mechanical action; in particular this implies that existing N-sp² C sites are beginning to cluster as temperature increases.     

Development of amorphous carbon coating with luminescent silica/CdSe/ZnS quantum dots underlayer for wear monitoring

Amorphous carbon (a-C) coating with luminescent wear-sensing underlayer is developed for achieving the tribological coating with wear monitoring capability. Wear monitoring of a-C coating by luminescent spectroscopy to determine the remaining thickness of the coating after the wear test is also demonstrated. The coating structure consists of a-C films deposited by R.F. magnetron sputtering method onto the luminescent layer, which is made from silica coating containing CdSe/ZnS quantum dots (Silica/QD). A thin Si-intermediate layer is added between a-C and silica/QD layer for adhesion improvement. The physical as well as tribological properties of the coatings are analysed. Furthermore, wear monitoring of a-C films is also demonstrated to determine the remaining coating thickness after the tribological test. The demonstration is carried out by firstly formulating a relation between luminescent intensity detected from the coating and coating thickness. Then the luminescent intensity is measured again from the wear track. The remaining thickness is finally determined by using the relationship between luminescent intensity and coating thickness. The fabricated coating exhibits a smooth surface with the average surface roughness of 1.35 nm and a friction coefficient of 0.1. The demonstration of wear monitoring shows that the remaining thickness of the coating after the tribological test determined by luminescent spectroscopy is compared well with the thickness measured by profilometry. This suggests that wear monitoring of a-C films by luminescent spectroscopy technique is feasible.     

Ultra-High Tribological Performance of Magnetron Sputtered a-C:H Films in Sand-Dust Environment

The hydrogenated amorphous carbon (a-C:H) films were prepared on AISI 440C steel substrates using a RF magnetron sputtering graphite target in the CH₄ and Ar mixture atmosphere. The friction and wear behavior of a-C:H films were comparatively investigated by pin-on-disc tester under dry sliding and simulated sand-dust wear conditions. In addition, the effects of applied load, amount of sand and sand particle sizes on the tribological performance of a-C:H films were systemically studied. Results show that a-C:H films exhibited ultra-high tribological performance with low friction coefficient and ultra-low wear rate under sand-dust environments. It is very interesting to observe that the friction coefficient of a-C:H film under sand-dust conditions was relatively lower when compared with dry sliding condition, and the wear rate under sand-dust conditions kept at the same order of magnitude (×10⁻¹⁹ m³/N m) with the increase of applied load and particle size as a comparison with the dry sliding condition. Based on the formation of “ridge” layer (composite transfer layer), a transfer layer-hardening composite model was established to explain the anti-wear mechanisms and friction-reducing capacity of a-C:H solid lubrication films under sand-dust conditions.     

Tribological Properties of Nanocomposite CrC<Subscript><Emphasis Type="Italic">x</Emphasis></Subscript>/a-C:H Thin Films

Recently we showed that coatings, prepared by unbalanced magnetron sputtering from a metallic Cr target in an Ar/CH₄ discharge are composed of nanocrystalline CrC _x embedded in an a-C:H matrix. This work investigates the structural correlation of such nanocomposite CrC _x /a-C:H coatings to their tribological properties. Raman spectroscopy and X-ray photoelectron spectroscopy (XPS) were used to characterize the phase composition and the chemical bonding in the films deposited at different experimental conditions. The coating microstructure was investigated on selected samples by high-resolution transmission electron microscopy. For CrC _x -dominated coatings deposited at CH₄ partial to total pressure ratios (p_CH4/p_t) < 0.42, only minor changes regarding the friction coefficients and the abrasive wear rates were observed although microstructural changes towards a higher degree of crystallinity were proven by transmission electron microscopy and substantiated with XPS results. For a-C:H dominated coatings deposited at p_CH4/p_t > 0.42, the friction coefficients and abrasive wear rates were shown to decrease with increasing a-C:H phase content and its more sp²-like bonding configuration. It can be concluded that the microstructural changes in terms of CrC _x crystallite coarsening and bonding configuration of the a-C:H matrix phase are responsible for the observed changes of the friction coefficients and wear rates.     

Tribological Performance of Halogen-Free Ionic Liquids in Steel–Steel and DLC–DLC Contacts

The tribological performance of halogen-free ionic liquids at steel–steel and diamond-like carbon (DLC)–DLC contacts was investigated. Hydrogenated amorphous carbon (a-C:H) and tetrahedral amorphous carbon (ta-C) were used as test specimens. Friction tests were carried out on steel–steel, a-C:H–a-C:H, and ta-C–ta-C contacts by using a reciprocating cylinder-on-disk tribotester lubricated with two different types of halogen-free ionic liquids: 1-ethyl-3-methylimidazolium dicyanamide ([BMIM][DCN]) and 1-butyl-3-methylimidazolium tricyanomethanide ([BMIM][TCC]). From the results of friction tests, the ta-C–ta-C tribopair lubricated with [BMIM][DCN] or [BMIM][TCC] exhibited an ultralow friction coefficient of 0.018–0.03. On the other hand, ultralow friction was not observed at the steel–steel and a-C:H–a-C:H contacts. Measurements obtained with a laser scanning microscope and an atomic force microscope (AFM) showed that a chemical reaction film, derived from the ionic liquid lubricant used, was formed on the steel surfaces. However, this chemical reaction film was not observed on either of the DLC surfaces. The AFM results showed that there were high-viscosity products on the ta-C surfaces, that the wear tracks on the ta-C surfaces exhibited low frictional properties, and that the ta-C surfaces were extremely smooth after the friction tests. Based on these results, it was concluded that an ionic liquid–derived adsorbed film formed on the ta-C surface and resulted in the ultralow friction when lubricated with a halogen-free ionic liquid.     

Role of the Transfer Film on the Friction and Wear of Metal Carbide Reinforced Amorphous Carbon Coatings During Run-in

The relationship between friction, wear, and transfer films of three metal carbide-reinforced amorphous carbon coatings (TiC/a:C, TiC/a:C–H, and WC/a:C–H), sometimes referred to as metal-doped diamond-like carbon coatings, has been investigated. Tribological tests were performed in an in situ tribometer with sapphire or steel hemispheres run against coated flats in dry or ambient air. The sliding contact interface was observed and recorded by optical microscopy during reciprocating sliding tests. The friction and wear behavior during run-in depended on the number of sliding cycles to form a stationary transfer film on the hemisphere. Stationary transfer films formed rapidly (within ten cycles) and the friction coefficient fell to 0.2 (ambient air) or 0.1 (dry air), except with sapphire against WC/a:C–H in dry air; with the latter, a stationary transfer film required nearly 100 cycles to form, during which the friction remained high and the wear rate was from 10 to 100 times higher than the other two coatings. For all coatings, three velocity accommodation modes (VAM) were observed from run-in to steady-state sliding and were correlated with the friction and wear behavior. The delayed adherence of the transfer film to sapphire from WC/a:C–H coatings in dry air is discussed in terms of equilibrium thermochemistry. Friction and wear behavior during run-in, therefore, depended on transfer film adherence to the hemisphere and the VAM between transfer films and the coating.     

Low-friction carbon-rich carbide coatings deposited by co-sputtering

Low-friction coatings are used more and more frequently, particularly in situations and applications with insufficient or no lubrication. A good example of such coatings is amorphous carbon, which is produced both in pure form (a-C:H) and doped with metal (Me-C:H). The knowledge of what actually occurs when one metal in a Me-C:H coating is exchanged with another has so far been rather limited. Also, when producing these films hydrogen is incorporated in the substrate as well as in the film, which can be detrimental to the overall properties.Here, a newly adopted co-sputtering technique, utilizing a carbon target partly covered by metal-foil strips, was used to deposit non-hydrogenated carbon coatings alloyed with Ta, W and Zr on ball-bearing steel (BBS) substrates. The metal content varied between 0 and 41 at.%, and the resulting films were analyzed with respect to phase composition and textures, chemical composition, microstructural morphology, as well as mechanical and tribological properties. All alloyed coatings displayed a nanocomposite microstructure, with 3-6 nm metal-carbide crystallites embedded in a matrix of amorphous carbon. The amount of metal-carbide phase increased with increasing amounts of metal which led to a large increase in hardness and elastic modulus. An increased metal content did however not affect the carbide size to any notable extent. Ball-on-disk tests show that metal additions cause a sharp drop in friction coefficient from 0.21 to about 0.05, depending on the metal used. This is however accompanied by an increase in wear rate. The coating best combining low friction and low wear rate was alloyed with 20 at.% Ta. Best possible protection of the counter surface was offered by coatings containing 30 at.% Ta or more.     

Wear Initiation of 52100 Steel Sliding Against a Thin Boron Carbide Coating

Boron carbide (B₄C) is well known for its high hardness and wear resistance. It has been found to polish its mating surface and act as a run-in coating if one of the contacting surfaces is coated by B₄C. Employing such run-in coatings demands a thorough understanding of the initiation and development of the polishing process. This paper reports a study on the initiation and development of the surface wear of 52100 steel balls run against B₄C-coated disks. The evolution of the steel surface wear scar and evolution of the contact pressure contours are utilized in connection with changes in the plastically deformed area in order to gain insight into the wear development. Furthermore, variations of fractal parameters of the steel surface and the overall topothesy, which is a measure of the surface anisotropy, are examined in connection with the wear process.     

Diamond-like carbon coatings with nanocomposite structure formed by reactive magnetron sputtering of chrome in an Ar + C2H2 + N2 gas mixture and their tribological behavior

Results of a complex study of the structure, the phase and chemical compositions, the microhardness, as well as the nanomechanical and tribological properties of a-C: H: Cr: N hydrogenated amorphous carbon coatings are presented; these coatings were formed by the reactive magnetron sputtering of chromium at various concentrations of nitrogen and acetylene in the active Ar + C₂H₂ + N₂ gas mixture. Raman spectroscopy has shown that carbon in these coatings is represented by a disordered mixture of regions with tetrahedral (sp ³) and hexagonal (sp ²) coordination of carbon atoms. The alloying metal in the coating formed nanosized inclusions of metal chrome, as well as of its carbide and nitride phases. It has been shown that the additional alloying of a-C: H: Cr coatings with nitrogen, which leads to the formation of chromium nitride, makes it possible to improve their mechanical and tribological characteristics.     

Durability of ZDDP Tribofilms Formed in DLC/DLC Contacts

The tribological properties of diamond-like carbon (DLC) coatings have drawn much attention of OEMs and lubricant manufacturers in recent years. It is important to know whether conventional friction modifier and antiwear additives can form durable films and work as effectively with DLCs as they normally do on steel surfaces. In this study, the film-forming and friction properties of the antiwear additive ZDDP and the strength of tribofilms formed by this additive on five widely used DLC types, namely a-C:H, a-C:H:W, a-C:H:WC, Si-DLC and ta-C, have been investigated. It is found that ZDDP-derived tribofilms form on all the DLCs but exhibit different friction characteristics based on DLC type. With all DLCs, the amount of tribofilm elements measured after durability tests was less than that measured initially. Over 90 % of thiophosphate and 70 % of sulphide/sulphate were lost during durability tests. ZDDP tribofilms were found to be strongly adhered on Si-DLC and a-C:H compared with the other DLCs. The ZDDP tribofilms formed in DLC/DLC contact appear to be similar in structure to those formed in steel/steel contact but not to exhibit the antiwear performance seen in steel/steel contacts.     

Relationship between molecular structures and tribological properties of phosphazene lubricants

Cyclotriphosphazene lubricants were synthesized and the relationship between their structures and tribological properties was investigated using an optimol SRV oscillating friction and wear tester and one-way reciprocating friction tester. The elemental composition and chemical nature of the antiwear films generated on steel surface were analyzed on a scanning electron microscope with a Kevex energy dispersive X-ray analyzer attachment (SEM–EDS) and X-ray photoelectron spectrometer (XPS). It was found that aryloxyphosphazene with polar substituent as a lubricant of steel–steel and steel–aluminum pair gave low wear, while aryloxyphosphazene with nonpolar group on the phenyl pendant led to high wear. Phosphazene provides poor lubricity for the steel–aluminum system under low load (0.5–3 N). The XPS analytical results of the antiwear films generated on the steel and aluminum surface indicate that phosphazene reacted with steel or aluminum counterface and formed a surface protecting film consisting of fluoride and organic compounds containing O, C, F, N, and P during friction. This contributes to reduce the friction and wear of steel–aluminum system.     

The influence of surface roughness on friction and wear of machine element coatings

The use of low friction coatings like amorphous carbon or metal-doped carbon coatings on machine elements is constantly increasing. Most often, a surface treatment, e.g. grinding and polishing or honing, is required for optimal performance of the coated machine element. This can be time consuming and costly.In this study, the effect of surface roughness on friction and sliding wear of two different coatings, one tungsten containing and one chromium containing coating, were examined using a ball-on-disc test. Ball bearing steel plates were grinded to different surface roughnesses and coated with the two different coatings.The friction was found to depend on surface roughness where the rougher surfaces gave higher friction coefficients. The wear rate for the a-C:W coating was found to be independent of the roughness, whereas the roughness had a strong influence on the wear rate for the a-C:Cr coating. This could partly be explained by a difference in wear mechanism, where fatigue wear was observed for the a-C:Cr coating but not for the a-C:W coating.     

Abrasiveness Control of a Thin Boron Carbide Coating Through Counterpart Tempering

Boron carbide (B₄C) coatings have previously been studied for potential use as finite-life run-in coatings. B₄C itself exhibits high hardness and favorable wear resistance. In dry sliding wear, it polishes its counterpart mating surface and provides fatigue resistance to a coated part by removing asperities that would otherwise cause fatigue failure. Thus, the ability of these coatings to polish the counterpart mating surface is the critical property for their functioning as fatigue coatings. Employing such run-in coatings requires precise control of the changes in abrasiveness during the polishing process. This study found that the rate at which the coating abrasiveness decreases can be controlled by varying the tempering temperature of the steel counterpart. This paper discusses the underlying factors that contribute to these effects.     

Structural modification and tribological behavior improvement of solid lubricating WSe x coatings during pulsed laser deposition in buffer He-Gas

Thin film, solid lubricating WSe _x coatings were deposited at room temperature on a steel substrate with a titanium underlayer by pulsed laser deposition (PLD). Two modes of PLD were investigated, i.e., the PLD under vacuum conditions and the PLD in a buffer gas (helium) at a pressure of 2–10 Pa. Gas was used to slow down the laser-induced atomic flux and to modify thus the conditions of the coatings growth. At a pressure ～8 Pa, gas reduced the effectiveness of Se preferential sputtering by atomic flux, which resulted in the formation of coatings with a stoichiometric composition (x ≈ 2). The structure of the coatings was characterized by a greater degree of the perfect organization of atoms in the nanophase laminar packaging and reduced internal stresses. Studies by the ball-on-disk tests in humid air showed that the modification of the structure and the chemical composition of the coatings had a significant effect on their tribological behavior. Vacuum-deposited coatings fractured relatively quickly due to the cracking and delamination from the substrate surface along the sliding track. When the coatings deposited in helium were tested, wear by layer-by-layer removal was dominant, so the adhesive fracture was only observed in the local parts of the track. The simulation of the laser vapor deposition in the vacuum and in the buffer gas was performed. Likely factors that improve the tribological properties of the coating during deposition in the buffer gas were disclosed.     

A DOE nano-tribological study of thin amorphous carbon-based films

A design of experiment (DOE) matrix of 150 nm non-hydrogenated amorphous C and Cr doped amorphous C films was produced to investigate the effect of four key coating process parameters (use of an adhesion layer, Cr magnetron current, cathodic substrate bias voltage and Ar flow to the chamber) using a new rapid method of nano-scale wear test under conditions relevant to MEMS and similar devices. The condition of nano-wear was produced by controlled oscillation of the sample mounting within a nanoindentation system under ultra-low normal load. Specific wear rates were low, typically in the range 6-24×10⁻¹⁷ m³ N⁻¹ m⁻¹. The results were processed using an analysis of variance (ANOVA) procedure which showed that: hardness was reduced in the Cr containing films whilst specific wear rate and data scatter increased, increasing the cathodic substrate bias voltage reduced the specific wear rate due to increased coating hardness, the use of a Cr adhesion layer reduced the specific wear rate and scatter of results with Cr doped films but had no effect on pure a-C films, and Ar flow rate had no significant effect on specific wear rate but strongly interacted with the effect of the cathodic bias voltage.     

A comparison of the tribological behaviour of steel/steel, steel/DLC and DLC/DLC contacts when lubricated with mineral and biodegradable oils

Diamond-like carbon (DLC) coatings, which can nowadays be applied to many highly loaded mechanical components, sometimes need to operate under lubricated conditions. It is reasonable to expect that in steel/DLC contacts, at least the steel counter body will behave according to conventional lubrication mechanisms and will interact with lubricants and additives in the contact. However, in DLC/DLC contacts, such mechanisms are still unclear. For example, the “inertness” of DLC coatings raises several questions about whether they are able to provide real boundary “lubrication” or whether they are just a “passive” member in these contacts. On the other hand, biodegradable oils, in particular vegetable base oils, possess a good lubricating ability, often much better than mineral or conventional synthetic oils as a result of the large amount of un-saturated and polar components that can promote the lubricity of DLC coatings. Accordingly, in this study, we present the results of experiments under severe boundary-lubrication conditions during reciprocating sliding. We look at the effect of the type of mating surfaces - steel/DLC, DLC/DLC and steel/steel - and the type of oil on the tribological performance of DLC coatings. We compare the wear and friction behaviours of two types of DLC coatings, i.e., a “pure” non-doped a-C:H DLC coating (denoted as a-DLC) and a WC-containing multilayer coating (denoted as W-DLC) tested with a mineral oil and a biodegradable vegetable oil. These oils, which have very different chemical compositions, were used as base oils and also with mild AW and strong EP additives. Among other things, the results confirm the following: (1) coating/coating lubricated contacts can resemble metal-lubrication mechanisms; (2) additives reduce wear in coating/coating contacts by up to 80%; (3) better wear and friction performance are obtained with oils that contain large amounts of polar and un-saturated molecules; (4) a coating/coating combination generally results in less wear than a steel/coating combination.