Effect of composition on friction coefficient of Cu–graphite composites

Cu–graphite composites were prepared by hot isostatic pressing from the copper and graphite powders in the range of 0–50 vol.% of graphite. The same graphite powder was copper coated and used for the preparation of coated composites with 30 and 50 vol.% of graphite. It was confirmed that with increasing concentration of graphite the coefficient of friction and wear rate of coated and uncoated composites at first decreases. When critical concentration threshold of graphite is reached the coefficient of friction of composites becomes independent on the composition while the wear rate decreases further. This threshold is not simply 20 vol.% of graphite as stated [P.K. Rohatgi, S. Ray, Y. Liu, Tribological properties of metal matrix graphite particle composites, Int. Mater. Rev. 37 (1992) 129–149.] for metal matrix composites, but it significantly depends on the composite structure: for uncoated composites, it is 12 vol.% of graphite for fine graphite powder (16 μm), while for coarse powder (25–40 μm, [S.F. Moustafa, S.A. El-Badry, A.M. Sanad, B. Kieback, Friction and wear of copper–graphite composites made with Cu-coated and uncoated graphite powders, Wear 253 (2002) 699–710.]) it is 23 vol.% of graphite. For coated composites the concentration threshold was found above 25 vol.% of graphite. The reason is that the increased number of fine copper debris within graphite rich tribolayer occurs homogeneously also at high graphite composition.     

Friction and wear properties of Ni–Cr–W–Al–Ti–MoS2 at elevated temperatures and self-consumption phenomena

The composites of Ni–Cr–W–Al–Ti–MoS₂ with different adding amount of molybdenum disulfide (6–20 wt.%) were prepared by powder metallurgy (P/M) method. Their mechanical properties and tribological properties from room temperature to 600 °C were tested by a pin-on-disk tribometer. The effects of amounts of molybdenum disulfide, temperature, load, and speed on the friction and wear properties of composite were discussed. Besides, the tribological properties against different counterface materials, such as alumina, silicon nitride and nickel-iron-sulfide alloys were also investigated. Results indicated that the molybdenum disulfide was decomposed during the hot-press process and the eutectic sulfides of chromium were formed. The hardness and anti-bending strength can be improved by adding 6 wt.% molybdenum disulfide due to reinforcement of molybdenum. The friction coefficients and wear rates of composites decrease with the increase of adding amount of molybdenum disulfide until a critical value of 12 wt.%. The composite with 12% MoS₂ shows the optimum friction and wear properties over the temperature range of RT 600 °C. The friction coefficients of composite with 12% MoS₂ decrease with the increase of temperature, load, and sliding speed, while the wear rates increase with the increasing temperature and are insensitive to the sliding speed and load. The friction coefficients of less than 0.20 at 600 °C and mean wear rates of 10⁻⁵ mm³/N m are obtained when rubbing against alumina due to the lubrication of sulfide films and glaze layer formed on the friction surface at high temperature, while a relatively low wear rate of around 10⁻⁶ mm³/N m presents when rubbing against nickel-iron-sulfide alloys. At high temperature, wear rates of composite containing sulfide are inversely proportional to friction coefficients approximately.     

Friction and wear characteristics of ion-beam modified graphite coatings

Solid lubricated surfaces are now widely used in the tool industry, and the new concept of ‘soft tools’ recently introduced has emphasized low-friction surfaces. The present paper deals with a novel ‘burnishing’ process based on ionic bombardment of powder graphite coating/substrate systems. This process may influence both the coating and the coating/substrate interface, and it is effective for improving lubrication even at low doses of bombarding ions. The present study will discuss the friction and wear properties of graphite-powder coatings on a silicon wafer bombarded with 200 keV ion beams of argon, nitrogen and hydrogen ions, the last two as molecular ions. The coefficients of friction and wear rates of the coatings were found to be strongly dependent on the ion-bombarding species and ion dose. The argon ion bombardment increased the coefficient of friction and wear rate of the powder coating. However, at the interface of the silicon substrate, the ion-induced burnishing improved the tribological behaviour of the silicon material. Bombardment with nitrogen and hydrogen ions showed a marked improvement in the tribological properties of the graphite powder coating. Thus a reduction in wear rate by three orders of magnitude was observed in the case of nitrogen, and for both ions it was noted that ion-beam burnished graphite was lubricating in a dry environment, which has not been reported previously. The perspectives of ion bombardment as a burnishing process will be discussed and the observed effects will be qualitatively explained in the context of the theory for ionic penetration into solids.     

Three-body abrasive wear of TiC–NiMo cermets

The mechanism of three-body abrasive wear of TiC-base cermets was studied. The wear rate of a series of cermets with different percentage of NiMo binder phase (20–60 wt%) was studied. Silica sand was used as an abrasive. The wear rate of the cermets decreases with the increase of TiC and Mo content, which corresponds to the increase in the bulk hardness. The post-run wear tracks of the worn blocks were analyzed with SEM. The material is removed by several processes such as extrusion and removal of the binder and also fractures of the carbide grains and the carbide network.     

Influence of surface roughness on friction and scuffing behaviour of cast iron under sparse lubrication

Friction and scuffing behaviour of grey cast iron as influenced by the surface roughness under sparse lubrication conditions is studied. The studies are carried out on a three-shoe-on-disc machine under the conditions of parallel sliding. The experiments were conducted at three oil supply rates of 0.10, 0.22 and 0.36 μg/cm² per contact obtained through a mist oiling system and with specimens of cast iron shoes of different roughness values, Ra, between 0.04 and 2.0 μm against a 0.55% C steel disc. In a step load procedure, the friction torque at the end of each load step and the scuffing load are the major parameters measured. Results of friction and scuffing behaviour as a function of roughness and oil supply rates have been discussed.     

Friction and wear properties of Babbitt alloy 16-16-2 under sea water environment

The tribological behaviors of Babbitt alloy 16-16-2 sliding against aluminum bronze ZCuAl9Mn2 lubricated by sea water were systematically investigated in this paper. The results indicated that the friction coefficient decreased as the load increased to 30 N and then remained at a steady level at high loads, but decreased with increase in sliding speed. The wear rate increased with load, but decreased with sliding speed. The formation of basic lead carbonate Pb₃(OH)₂(CO₃)₂ during the sliding process played a critical role in the remaining low friction coefficient in sea water.     

Tribological properties of flame sprayed Fe–Ni–RE alloy coatings under reciprocating sliding

Fe–Ni–RE self-fluxing alloy powders were flame sprayed onto 1045 carbon steel. The tribological properties of Fe–Ni–RE alloy coatings under dry sliding against SAE52100 steel at ambient conditions were studied on an Optimol SRV oscillating friction and wear tester in a ball-on-disc contact configuration. Effects of load and sliding speed on tribological properties of the Fe–Ni–RE coatings were investigated. The worn surfaces of the Fe–Ni–RE alloy coatings were examined with a scanning electron microscopy(SEM) and an energy-dispersive spectroscopy(EDS). It was found that the Fe–Ni–RE alloy coatings had better wear resistance than the SAE52100 steel. An adhered oxide debris layer was formed on the worn surface in friction. Area of the friction layer varied with variety of sliding speed, but did not vary with load. The oxide layer contributed to decreased wear, but increased friction. Wear rate of the material increased with the load, but dramatically decreased at first and then slightly decreased the sliding speed. The friction coefficient of the material was 0.40-0.58, and decreased slightly with the load, but increased with sliding speed at first, and then tended to be a constant value. Wear mechanism of the coatings was oxidation wear and a large amount of counterpart material was transferred to the coatings.     

Friction of PM ferritic stainless steels at temperatures up to 300 °C

Two ferritic stainless steels (409Nb and 434L) manufactured through powder metallurgical techniques were wear tested at different temperature conditions (up to 300 °C). Two sliding speeds were used, and tests were carried out against a wrought austenitic stainless steel. Materials’ wear performance was characterized through friction coefficients and analysis of wear tracks was carried out through scanning electron microscopy. Results have shown an adhesive wear mechanism. Oxidized ferrite particles have also been found on wear tracks.     

Micromechanics and electrical conductivity of point contacts in boundary lubrication

Research methods based on recording parameters of electrical conductivity are considered for future application in nanotribology. Design relationships of conductivity are presented for idealized models of interface under conditions of boundary lubrication; contributions of various conductivity types in the total contact conductivity are estimated. An application methodology is described for the methods to study the properties of boundary lubricating layers. Some of the results obtained from the study of strength and frictional properties of boundary lubricating nanometre layers under normal load and sliding conditions are discussed.     

Friction characteristics of inorganic or organic thin coatings on solid surfaces under water lubrication

Water has been considered as an alternative working fluid for hydraulic power systems in order to minimize the consumption of fossil fuels and mineral oils. In spite of the many advantages to this use of water, difficult technical problems remain. The key technology for establishing a water hydraulic system is tribology, because water has a lack of lubricity, and thus some coating is needed to protect the metal surfaces from corrosion and frictional wear when using water as a lubricant. It has already been demonstrated that some Si-containing materials have good lubricity in a water environment. Recently, it has been shown that diamond-like carbon (DLC) coatings also have good lubricity with water. In order to clarify the mechanism by which such materials are lubricated with water, and to develop surface coatings that have good lubricity with water, the friction characteristic of several coated metals were investigated in this study. Coatings of CrN, CrSiN, and two types of DLC were applied on an SUS630 stainless steel flat disk substrate. Additive-free distilled water was used as a lubricating fluid. The friction characteristics of these coatings at different sliding speeds were evaluated using a tribometer with two contact configurations in which stainless steel balls and a flat ring without coatings were used as mating specimens.In addition, the lubrication characteristics of organic hydro-gels such as alginic acid or its metal salt were studied by immobilizing them on the surface, and their effects on the lubrication with water were discussed.     

Tribological properties and lubrication mechanisms of a Ag–Mo composite

A composite material containing silver and molybdenum metals was fabricated by powder metallurgy method with a Ag/Mo molar ratio of 2 : 1 and the sintering temperature is 700°C. Tribological properties, especially the solid lubrication behaviours during oxidation of the composite in air, were considered from room temperature to 600°C. Phase composition, microstructure and thermal behaviour of the composite were analysed before and after tests to investigate the lubrication mechanisms. The friction coefficients of the composite are ~0.7 below 400°C but decrease sharply to ~0.18 above 500°C. Characterisations of this composite indicate that several silver molybdates (Ag₂MoO₄, Ag₂Mo₂O₇ and Ag₂Mo₄O₁₃) formed from oxidation of Ag–Mo composite at high temperatures benefit lubrication effects and lead to the decrease of friction coefficients. Formation mechanism of these silver molybdates during oxidation and wear was therefore studied, and a model based on solid reaction processes in the Ag–Mo–O₂ system was promoted. Copyright © 2015 John Wiley & Sons, Ltd.     

Influence of surface roughness on normal-sliding lubrication

Contact between machine components can involve normal, sliding and rolling motion, either singly or in combination. Combined normal and sliding motion, which occur for example in the meshing of gear teeth and in heavily-loaded rolling elements, can present problems for lubrication. The purpose of the present experimental study was to investigate how surface roughness affects the lubricant film characteristics under conditions of combined normal and sliding motion. The experimental arrar gement consisted of a rotating roller which impacted a stationary ball in the presence of a lubricant. Under the same conditions of normal surface approach, increasing the surface roughness significantly decreased the level of roller sliding that could occur without breakdown of the lubricating film. This behaviour was similar to a step function. Of the several surface roughness parameters investigated, only those which involved the maximum peak-to-valley height correlated well with experimental results. In general, surface roughness had a greater effect on oil film breakdown than did either viscosity or load.     

Thermal and non-Newtonian analysis on mixed liquid–solid lubrication

A mixed liquid–solid lubrication theory is proposed which concerns the effect of solid particle, liquid lubricant and rubbing surface topography. Especially, it focuses on the circumstances when particle diameter, surface composite roughness and oil film thickness are in the same order of magnitude. A mathematical model containing Reynolds equation, particle load carrying equation, asperity contact equation and heat balance equation is constructed to simulate the mixed liquid–solid lubrication. Moreover, the introduction of non-Newtonian constitutive equation and the rheological parameters related to heat and pressure makes the model closer to practical application. Some typical examples have been analyzed to explore the characteristics of mixed liquid–solid lubrication. In these examples, the effects of the mixed liquid–solid lubricant, the particle diameter and mass concentration, the surface composite roughness, and the material properties are discussed. The simulating results are accordant with early experimental researches, which indicated that the mathematical model is in agreement with the practical mixed liquid–solid lubrication. The input parameters in the examples can be adjusted to adapt to versatile applications.     

Friction and wear of diamond-containing polyimide composites in water and air

Polyimide-based composites containing fine diamond powder were fabricated using spark plasma sintering. The based material was polyimide (PI) containing a small amount of polytetrafluoroethylene (PTFE). Two types of diamond powder were used: one synthesized by statically high pressure, i.e., high-pressure diamond (HD), and the other synthesized by shock compression, i.e., shock-compression diamond (SD). We evaluated their tribological properties using a reciprocating friction tester in water and air using an Al₂O₃ mating ball. Adding HD to the polyimide-PTFE-based material decreased the composite's friction in water, but the effect of this addition in air was negligible. The specific wear rate of composites with different HD content was similar to that of the based material alone in water, while the wear of composites decreased with the addition of diamond in air. The effect of diamond powder size on friction and wear of composites was generally low in both water and air. The addition of SD decreased the friction coefficient of composites, but SD content only negligibly affected the friction in water and air. The specific wear rate was minimal at SD content of 5 vol.%, when diamond content was varied. Wear was almost independent of diamond powder size. SD reduced composite friction and wear better than HD; regardless of environment, its friction coefficient was less than 0.1 and the specific wear rate was in the level of 10⁻⁷ mm³/N m in both water and air.     

The effect of brush spring pressure on the wear behaviour of copper–graphite brushes with electrical current

Electrical brushes are used to conduct current between stationary part and moving part of a motor or a generator. To ensure proper current transfer and continuous contact, brushes must be loaded against the sliding contact surface with a sufficient force. High loads increase frictional losses and wear of the brushes and/or sliding surface. While relatively low contact pressure causes arcing and higher voltage drop.In this study, a novel pin-on-slip ring-type friction and wear test machine was designed and manufactured for the purpose of brush testing. Copper–graphite-based electrical brush containing 90 wt% copper and 10 wt% graphite was manufactured by powder metallurgy and the tribological behaviour and voltage drop were investigated at different brush spring pressures at 10–200 kPa with current.It was found that the specific wear curve showed three distinct wear rate regimes, such as low, mild, and severe. Severe wear was observed below 30 kPa and above 120 kPa brush spring pressures (BSP) (3 and 12 N loads, respectively). Arc erosion was the main wear mechanism below 30 kPa brush spring pressure while abrasion was dominant above 120 kPa BSP. Low and mild regimes were observed between 30–50 and 50–120 kPa BSP, respectively. SEM observations showed that a continuous surface layer was formed at the sliding surfaces of the wear samples in low and mild wear regimes. The wear debris was examined by SEM and X-ray diffractometer.     

Friction and wear behavior of diamond-like carbon coating on plasma nitrided mild steel under boundary lubrication

The friction and wear properties of synthetic ionic liquid functionalized borate esters as additives in poly-alpha-olefin (PAO) were measured for diamond-like carbon (DLC) coating on plasma nitrided AISI 1045 steel. Results show that the borate esters gave much better friction–reduction and antiwear properties for DLC coating/steel and DLC coating/DLC coating sliding pairs than zinc dialkyldithiophosphate (ZDDP). In addition the DLC coating had much better wear resistance than the nitrided mild steel substrate, indicating that duplicate surface modification was more effective in significantly increasing the wear resistance of mild steel.     

纳米级金属粉对润滑油摩擦磨损性能的影响

在ＭＨＫ－５００型环块摩擦磨损试验机上,研究了纳米级金属粉加入到矿物油中的润滑性能,结果表明, 加有纳米级金属粉的润滑油表现出优良的抗磨性能,三乙醇胺与铜粉复配具有复合效应。     

Multilevel solution for thermal elastohydrodynamic lubrication of rolling/sliding circular contacts

A fast multigrid approach is presented for the analysis of thermal elastohydrodynamic lubrication (EHL) under rolling/sliding circular contacts at high loads and high slip ratios with low computing time on a personal computer. This fast solver combines directiteration, multigrid, Newton-Raphson, Gauss-Seidel iteration, and multilevel multi-integration methods into one working environment that can reduce the computational complexity from O(n³ to O(nlnn) for the thermal EHL problem under rolling/sliding circular contacts. Since the couped Reynolds and energy equations are simultaneously solved by the Newton-Raphson scheme, the iteration for the convergence solution is less than those of the classical approach. Results show that thermal effects on the pressure profile and film thickness are significant for a wide range of loads, speeds and slip ratios. The maximum midfilm and surface temperature rise in the Hertzian contact region increases with increasing slip ratio, dimensionless speed, and load. The minimum film thickness decreases with increasing load and slip ratio, and decreasing dimensionless speed.     

Dry and minimum quantity lubrication high-throughput drilling of compacted graphite iron

This research studies the sustainable and high-throughput drilling of compacted graphite iron (CGI), a high strength, lightweight material for automotive powertrain applications. CGI drilling experiments were conducted using a 4 mm diameter coated carbide drill at 26.5 mm/s feed rate. In two repeated tests under three lubrication conditions: dry, dry with through-the-drill compressed air, and through-the-drill minimum quantity lubrication (MQL), the drills were able to produce a maximum of 1,740, 3,150 and 2,948 holes, respectively, before the breakage of the drill. The Joule–Thomson effect due to the expansion of high pressure air from through-the-drill holes at the drill tip, chip shape, chip size and chip speed are investigated. Flank wear of the drill cutting edge is measured and results are correlated to drill life. Results indicate that dry machining of CGI is technically feasible. Chip evacuation and advanced tool cooling are important factors that affect drill life for high-throughput sustainable dry drilling of CGI.