Abstract: Cathodic plasma electrolysis (CPE) is used to create surface textures on cast iron samples for improving the tribological properties. Micro craters with confined size distribution were successfully formed by CPE process. These craters can generate extra hydrodynamic pressure that separates two sliding surfaces, increase the oil film thickness and accelerate the transition from boundary to mixed lubrication. It was found that the optimal crater size was 1.7 μm, at which the maximum lubrication efficiency was achieved. The Taguchi method was used to optimize the process parameters (voltage and roughness) for CPE surface texturing. The orthogonal array and the signal-to-noise ratio were employed to study the effect of each process parameter on the coefficient of friction. The results showed that with higher voltage and lower roughness, the lower friction coefficient can be obtained, and thus the lubrication can be more efficiently used for friction reduction.
Abstract: This work aims to investigate the properties and microstructure of diamond-like carbon film deposited by pulsed laser deposition by ablation of a graphite target in a vacuum chamber on a steel substrate. The equipment was mounted to provide one laser beam. The target of high purity graphite and the steel substrate were polished. The mechanical and tribological properties of the film were characterized using Raman spectroscopy, nanoindentation test, scratch test, roughness profile, tribometer, optical microscopy and SEM images. It was concluded that the pulsed laser deposition (PLD) technique associated with the low-pressure chamber and a graphite target provides a good fraction of sp3 bonding, that the process variable as surface polishing and laser parameter have great influence in tribological properties and in adherence tests performance. The optical microscopy images are efficient to identify the metallurgical bond.
Abstract: The tribological tests were performed on a new
tribometer, in order to measure the coefficient of friction of a gland
seal packing material on stainless steel shafts in presence of Cellulose
Nanocrystal (CNC) suspension as a sustainable, environmentally
friendly, water-based lubricant. To simulate the real situation from the
slurry pumps, silica sands were used as slurry particles. The surface
profiles after tests were measured by interferometer microscope to
characterize the surface wear. Moreover, the coefficient of friction
and surface wear were measured between stainless steel shaft and
chrome steel ball to investigate the tribological effects of CNC in
boundary lubrication region. Alignment of nanoparticles in the CNC suspensions are the
main reason for friction and wear reduction. The homogeneous
concentrated suspensions showed fingerprint patterns of a chiral
nematic liquid crystal. These properties made CNC a very good
lubricant additive in water.
Abstract: The tribological behavior of commercially used Perspex was evaluated under dry and wet sliding condition using a pin-on-disc wear tester with different applied loads ranging from 2.5 to 20 N. Experiments were conducted with varying sliding distance from 0.2 km to 4.6 km, wherein the sliding velocity was kept constant, 0.64 ms-1. The results reveal that the weight loss increases with applied load and the sliding distance. The nature of the wear rate was very similar in both the sliding environments in which initially the wear rate increased very rapidly with increasing sliding distance and then progressed to a slower rate. Moreover, the wear rate in wet sliding environment was significantly lower than that under dry sliding condition. The worn surfaces were characterized by optical microscope and SEM. It is found that surface modification has significant effect on sliding wear performance of Perspex.
Abstract: Ductile iron samples alloyed with 2.5% Si, 0.78% Cu, 0.421% Mo and 0.151% Ni were austempered at 345 °C and 380 °C for 150 and 180 mins and then tested for wear strength. Ductile iron was also included in the study for comparison purposes. A pin-on-disc machine was employed for wear study. The investigations were carried out for a speed of 3 m/s, under the contact load of 29.43 N with varying sliding distances ranging from 1000 m to 5000 m. The experimental outcome indicates that ADI austempered at 345 °C is more wear resistant than the one austempered at 380 °C. Also for only a sliding distance of 3000 m, both exhibited almost same wear resistance. SEM analysis indicates running sliding marks more or less parallel to one another. Spalled layers and large voids which resemble delamination were observed on worn surface of ADI380. This indicated the occurrence of severe wear. Dark patches observed indicate oxidized surface.
Abstract: Nitrogen implantation in aluminum and its alloys is acquainted for the difficulties in obtaining modified layers deeper than 200 nm. The present work addresses a new method to overcome such a problem; although, the coating with nitrogen and oxygen obtained by plasma immersion ion implantation (PIII) into a 7075 aluminum alloy surface was too shallow. This alloy is commonly used for structural parts in aerospace applications. Such a layer was characterized by secondary ion mass spectroscopy, electron microscopy, and nanoindentation experiments reciprocating wear tests. From the results, one can assume that the wear of this aluminum alloy starts presenting severe abrasive wear followed by an additional adhesive mechanism. PIII produced a slight difference, as shown in all characterizations carried out in this work. The results shown here can be used as the scientific basis for further nitrogen PIII experiments in aluminum alloys which have the goal to produce thicker modified layers or to improve their surface properties.
Abstract: Around the globe, there is demand for the development of bio-based lubricant which will be biodegradable, non -toxic and environmental friendly. This paper outlines the friction and wear characteristics of Pongamia oil (PO) contaminated bio-lubricant by using pin-on-disc tribometer. To formulate the bio-lubricants, PO was blended in the ratios 15, 30 and 50% by volume with the base lubricant SAE 20 W 40. Tribological characteristics of these blends were carried out at 3.8 m/s sliding velocity and loads applied were 50, 100, 150 N. Experimental results showed that the lubrication regime that occurred during the test was boundary lubrication while the main wear mechanisms were abrasive and the adhesive wear. During testing, the lowest wear was found with the addition of 15% PO, and above this contamination, the wear rate was increased considerably. With increase in load, viscosity of all the bio-lubricants increases and meets the ISO VG 100 requirement at 40 oC except PB 50. The addition of PO in the base lubricant acted as a very good lubricant additive which reduced the friction and wear scar diameter during the test. It has been concluded that the PB 15 can act as an alternative lubricant to increase the mechanical efficiency at 3.8 m/s sliding velocity and contribute in reduction of dependence on the petroleum based products.
Abstract: Shear stresses generate frictional forces thus lead to the reduction of engine performance due to the power losses. This friction can also cause damage to the piston material. Thus, the choice of an optimal material for the piston is necessary to improve the elastohydrodynamical contacts of the piston. In this study, to achieve this objective, an elastohydrodynamical lubrication model that satisfies the best tribological behavior of the piston with the optimum choice of material is developed. Several aluminum alloys composed of different components are studied in this simulation. An application is made on the piston 60 x 120 mm Diesel engine type F8L413 currently mounted on Deutz trucks TB230 by using different aluminum alloys where alloys based on aluminum-silicon have better tribological performance.
Abstract: The present work aims at contributing to the study of the complex phenomenon of wear of pin on disc contact in dry sliding friction between two material couples (bronze/steel and unsaturated polyester virgin and charged with graphite powder/steel). The work consists of the determination of the coefficient of friction, the study of the influence of the tribological parameters on this coefficient and the determination of the mass loss and the wear rate of the pin. This study is also widened to the highlighting of the influence of the addition of graphite powder on the tribological properties of the polymer constituting the pin. The experiments are carried out on a pin-disc type tribometer that we have designed and manufactured. Tests are conducted according to the standards DIN 50321 and DIN EN 50324. The discs are made of annealed XC48 steel and quenched and tempered XC48 steel. The main results are described here after. The increase of the normal load and the sliding speed causes the increase of the friction coefficient, whereas the increase of the percentage of graphite and the hardness of the disc surface contributes to its reduction. The mass loss also increases with the normal load. The influence of the normal load on the friction coefficient is more significant than that of the sliding speed. The effect of the sliding speed decreases for large speed values. The increase of the amount of graphite powder leads to a decrease of the coefficient of friction, the mass loss and the wear rate. The addition of graphite to the UP resin is beneficial; it plays the role of solid lubricant.
Abstract: Tribological properties that include nanoparticles are an alternative to improve the tribological behaviour of lubricating oil, which has been investigated by many researchers for the past few decades. Various nanostructures can be used as additives for tribological improvement. However, this also depends on the characteristics of the nanoparticles. In this study, tribological investigation was performed to examine the effect of CuO nanoparticles on the tribological behaviour of Syntium 800 SL 10W−30. Three parameters used in the analysis using the wear tester (piston ring) were load, revolutions per minute (rpm), and concentration. The specifications of the nanoparticles, such as size, concentration, hardness, and shape, can affect the tribological behaviour of the lubricant. The friction and wear experiment was conducted using a tribo-tester and the Response Surface Methodology method was used to analyse any improvement of the performance. Therefore, two concentrations of 40 nm nanoparticles were used to conduct the experiments, namely, 0.005 wt % and 0.01 wt % and compared with base oil 0 wt % (control). A water bath sonicator was used to disperse the nanoparticles in base oil, while a tribo-tester was used to measure the coefficient of friction and wear rate. In addition, the thermal properties of the nanolubricant were also measured. The results have shown that the thermal conductivity of the nanolubricant was increased when compared with the base oil. Therefore, the results indicated that CuO nanoparticles had improved the tribological behaviour as well as the thermal properties of the nanolubricant oil.
Abstract: The tribological test with Pin-On-Disc configuration
measures friction and wear properties in dry or lubricated sliding
surfaces of a variety of materials and coatings. Polymeric matrix
composites loaded with mineral filler were used, 1%, 3%, 10%, 30%,
and 50% mass percentage of filler, to reduce the material cost by
using mineral tailings. Using a pin-on-disc tribometer to quantify
coefficient of friction and wear resistance of the specimens. The
parameters known to performing the test were 300 rpm rotation,
normal load of 16N and duration of 33.5 minutes. The composite
with 10% mineral filler performed better, considering that the wear
resistance was good when compared to the other compositions and an
average low coefficient of friction, in the order of μ ≤ 0.15.
Abstract: The use of titanium fluoride and iron fluoride
(TiF3/FeF3) catalysts in combination with polutetrafluoroethylene
(PTFE) in plain zinc- dialkyldithiophosphate (ZDDP) oil is important
for the study of engine tribocomponents and is increasingly a strategy
to improve the formation of tribofilm and provide low friction and
excellent wear protection in reduced phosphorus plain ZDDP oil. The
influence of surface roughness and the concentration of
TiF3/FeF3/PTFE were investigated using bearing steel samples
dipped in lubricant solution at 100°C for two different heating time
durations. This paper addresses the effects of water drop contact
angle using different surface; finishes after treating them with
different lubricant combination. The calculated water drop contact
angles were analyzed using Design of Experiment software (DOE)
and it was determined that a 0.05 μm Ra surface roughness would
provide an excellent TiF3/FeF3/PTFE coating for antiwear resistance
as reflected in the Scanning electron microscopy (SEM) images and
the tribological testing under extreme pressure conditions. Both
friction and wear performance depend greatly on the PTFE/and
catalysts in plain ZDDP oil with 0.05 % phosphorous and on the
surface finish of bearing steel. The friction and wear reducing effects,
which was observed in the tribological tests, indicated a better micro
lubrication effect of the 0.05 μm Ra surface roughness treated at
100°C for 24 hours when compared to the 0.1 μm Ra surface
roughness with the same treatment.
Abstract: Development of new generation bio-tribological,
multilayer coatings opens an avenue for fabrication of future hightech
functional surfaces. In the presented work, nano-composite,
Cr/CrN+[Cr/ a-C:H implanted by metallic nanocrystals] multilayer
coatings have been developed for surface protection of medical tools.
Thin films were fabricated by a hybrid Pulsed Laser Deposition
technique. Complex microstructure analysis of nanomultilayer
coatings, subjected to mechanical and biological tests, were
performed by means of transmission electron microscopy (TEM).
Microstructure characterization revealed the layered arrangement of
Cr23C6 nanoparticles in multilayer structure. Influence of deposition
conditions on bio-tribological properties of the coatings was studied.
The bio-tests were used as a screening tool for the analyzed
nanomultilayer coatings before they could be deposited on medical
tools. Bio-medical tests were done using fibroblasts. The mechanical
properties of the coatings were investigated by means of a ball-ondisc
mechanical test. The micro hardness was done using Berkovich
indenter. The scratch adhesion test was done using Rockwell
indenter. From the bio-tribological point of view, the optimal
properties had the C106_1 material.
Abstract: Electrodeposition is a simple and economic technique
for precision coating of different shaped substrates with pure metal,
alloy or composite films. Dc electrodeposition was used to produce
Cr, Co-Cr and Co-Cr/TiO2 nano-composite coatings from Cr(III)
based electrolytes onto 316L SS substrates. The effects of TiO2 nanoparticles
concentration on co-deposition of these particles along with
Cr content and microhardness of the coatings were investigated.
Morphology of the Cr, Co-Cr and Co-Cr/TiO2 coatings besides their
tribological behavior were studied. The results showed that increment
of TiO2 nanoparticles concentration from 0 to 30 g L-1 in the bath
increased their co-deposition and Cr content of the coatings from 0 to
3.5 wt.% and from 23.7 to 31.2 wt.%, respectively. Microhardness of
Cr coating was about 920 Hv which was higher than Co-Cr and even
Co-Cr/TiO2 films. Microhardness of Co-Cr and Co-Cr/TiO2 coatings
were improved by increasing their Cr and TiO2 content. All the
coatings had nodular morphology and contained microcracks.
Nodules sizes and the number of microcracks in the alloy and
composite coatings were lower than the Cr film. Wear results
revealed that the Co-Cr/TiO2 coating had the lowest wear loss
between all the samples, while the Cr film had the worst wear
resistance.
Abstract: Al6061 alloy base matrix, reinforced with particles of
silicon carbide (10 wt %) and Graphite powder (1wt%), known as
hybrid composites have been fabricated by liquid metallurgy route
(stir casting technique) and optimized at different parameters like
applied load, sliding speed and sliding distance by taguchi method. A
plan of experiment generated through taguchi technique was used to
perform experiments based on L27 orthogonal array. The developed
ANOVA and regression equations are used to find the optimum
coefficient of friction and wear under the influence of applied load,
sliding speed and sliding distance. On the basis of “smaller the best”
the dry sliding wear resistance was analysed and finally confirmation
tests were carried out to verify the experimental results.
Abstract: Vancron 40, a nitrided powder metallurgical tool
Steel, is used in cold work applications where the predominant failure
mechanisms are adhesive wear or galling. Typical applications of
Vancron 40 are among others fine blanking, cold extrusion, deep
drawing and cold work rolls for cluster mills. Vancron 40 positive
results for cold work rolls for cluster mills and as a tool for some
severe metal forming process makes it competitive compared to other
type of work rolls that require higher precision, among others in cold
rolling of thin stainless steel, which required high surface finish
quality. In this project, three roll materials for cold rolling of stainless
steel strip was examined, Vancron 40, Narva 12B (a high-carbon,
high-chromium tool steel alloyed with tungsten) and Supra 3 (a
Chromium-molybdenum tungsten-vanadium alloyed high speed
steel). The purpose of this project was to study the depth profiles of
the ironed stainless steel strips, emergence of galling and to study the
lubrication performance used by steel industries. Laboratory
experiments were conducted to examine scratch of the strip, galling
and surface roughness of the roll materials under severe tribological
conditions. The critical sliding length for onset of galling was
estimated for stainless steel with four different lubricants. Laboratory
experiments result of performance evaluation of resistance capability
of rolls toward adhesive wear under severe conditions for low and
high reductions. Vancron 40 in combination with cold rolling
lubricant gave good surface quality, prevents galling of
metal surfaces and good bearing capacity.
Abstract: Various biomass based resources, which can be used
as an extender, or a complete substitute of diesel fuel may have very
significant role in the development of agriculture, industrial and
transport sectors in the energy crisis. Use of Karanja oil methyl ester
biodiesel in a CI DI engine was found highly compatible with engine
performance along with lower exhaust emission as compared to
diesel fuel but with slightly higher NOx emission and low wear
characteristics. The combustion related properties of vegetable oils
are somewhat similar to diesel oil. Neat vegetable oils or their blends
with diesel, however, pose various long-term problems in
compression ignition engines. These undesirable features of
vegetable oils are because of their inherent properties like high
viscosity, low volatility, and polyunsaturated character. Pongamia
methyl ester (PME) was prepared by transesterification process using
methanol for long term engine operations. The physical and
combustion-related properties of the fuels thus developed were found
to be closer to that of the diesel. A neat biodiesel (PME) was selected
as a fuel for the tribological study of biofuels.
Two similar new engines were completely disassembled and
subjected to dimensioning of various vital moving parts and then
subjected to long-term endurance tests on neat biodiesel and diesel
respectively. After completion of the test, both the engines were
again disassembled for physical inspection and wear measurement of
various vital parts. The lubricating oil samples drawn from both
engines were subjected to atomic absorption spectroscopy (AAS) for
measurement of various wear metal traces present. The additional
lubricating property of biodiesel fuel due to higher viscosity as
compared to diesel fuel resulted in lower wear of moving parts and
thus improved the engine durability with a bio-diesel fuel. Results
reported from AAS tests confirmed substantially lower wear and thus
improved life for biodiesel operated engines.
Abstract: The tribological outcomes of micro dent are found to be outstanding in many engineering and natural surfaces. Ceramic (Al2O3) is considered one of the most potential material to bearing surfaces particularly, artificial hip or knee implant. A well-defined micro dent on alumina oxide interface could further decrease friction and wear rate, thus increase their stability and durability. In this study we fabricated circular micro dent surface profiles (Dia: 400µm, Depth 20µm, P: 1.5mm; Dia: 400µm, Depth 20µm, P: 2mm) on pure Al2O3 (99.6%) substrate by using a micro tool machines. A preliminary tribological experiment was carried out to compare friction coefficient of these fabricated dent surfaces with that of non-textured surfaces. The experiment was carried on well know pin-on-disk specimens while other experimental parameters such as hertz pressure, speed, lubrication, and temperature were maintained to standard of simulated hip joints condition. The experiment results revealed that micro dent surface texture reduced 15%, 8% and 4% friction coefficient under 0.132,0.162, 0.187 GPa contact pressure respectively. Since this is a preliminary tribological study, we will pursue further experiments considering higher ranges of dent profiles and longer run experiments. However, the preliminary results confirmed the suitability of fabricating dent profile to ceramic surfaces by using micro tooling, and also their improved tribological performance in simulated hip joints.
Abstract: In this paper, the application of thermal spray
coatings in high speed shafts by a revolution up to 23000 RPM
has been studied. Gas compressor shafts are worn in contact
zone with journal therefore will be undersized. Wear
mechanisms of compressor shaft were identified. The
predominant wear mechanism is abrasion wear. The worn
surface was coated by hard WC-Co cermets using high
velocity oxy fuel (HVOF) after preparation. The shafts were in
satisfactory service in 8000h period. The metallurgical and
Tribological studies has been made on the worn and coated
shaft using optical microscopy, scanning electron microscopy
(SEM) and X-ray diffraction.
Abstract: In this paper, the babbitting of a bearing in boiler feed pump of an electromotor has been studied. These bearings have an important role in reducing the shut down times in the pumps, compressors and turbines. The most conventional method in babbitting is casting as a melting method. The comparison between thermal spray and casting methods in babbitting shows that the thermal spraying babbitt layer has better performance and tribological behavior. The metallurgical and tribological analysis such as SEM, EDS and wet chemical analysis has been made in the Babbitt alloys and worn surfaces. Two type of babbitt materials: tinbase and lead-base babbitt was used. The benefits of thermally sprayed babbitt layers are completely clear especially in large bearings.