Surface morphology in engineering applications: Influence of roughness on sliding and wear in dry fretting

Influence of initial surface roughness on friction and wear processes under fretting conditions was investigated experimentally. Rough surfaces (Ra=0.15-2.52 [mu]m) were prepared on two materials: carbon alloy (AISI 1034) and titanium alloy (Ti-6Al-4V). Strong influence of initial surface roughness on friction and wear processes is reported for both tested materials. Lower coefficient of friction and increase in wear rate was observed for rough surfaces. Wear activation energy is increasing for smoother surfaces. Lower initial roughness of surface subjected to gross slip fretting can delay activation of wear process and reduce wear rate; however, it can slightly increase the coefficient of friction

Interface roughness effect on friction map under fretting contact conditions

In many industrial applications where fretting damage is observed in the contact (e.g. rotor/blade, electrical contacts, assembly joint, axe/wheel, clutch) the external loadings or geometry design cannot be changed. Therefore, the surface preparation and finishing process become essential to control and reduce the damage caused by fretting. In this paper, the authors present the experimental study of the initial surface roughness and machining process influence on fretting conditions in both partial and full sliding regimes. Surfaces prepared by milling and smooth abrasive polishing processes have been analysed. The influence of roughness on sliding behaviour and analysis of friction have been reported. Also, the contact pressure influence and qualitative analysis of fretting wear scar have been presented

Wetting of anisotropic sinusoidal surfaces - experimental and numerical study of directional spreading

Directional wettability, i.e. variation of wetting properties depending on the surface orientation, can be achieved by anisotropic surface texturing. A new high precision process can produce homogeneous sinusoidal surfaces (in particular parallel grooves) at the micro-scale, with a nano-scale residual roughness five orders of magnitude smaller than the texture features. Static wetting experiments have shown that this pattern, even with a very small aspect ratio, can induce a strong variation of contact angle depending on the direction of observation. A comparison with numerical simulations (using Surface Evolver software) shows good agreement and could be used to predict the fluid-solid interaction and droplet behaviour on textured surfaces. Two primary mechanisms of directional spreading of water droplets on textured stainless steel surface have been identified. The first one is the mechanical barrier created by the textured surface peaks, this limits spreading in perpendicular direction to the surface anisotropy. The second one is the capillary action inside the sinusoidal grooves accelerating spreading along the grooves. Spreading has been shown to depend strongly on the history of wetting and internal drop dynamics

Wettability versus roughness of engineering surfaces

Wetting of real engineering surfaces occurs in many industrial applications (liquid coating, lubrication, printing, painting, ...). Forced and natural wetting can be beneficial in many cases, providing lubrication and therefore reducing friction and wear. However the wettability of surfaces can be strongly affected by surface roughness. This influence can be very significant for static and dynamic wetting [1]. In this paper authors experimentally investigate the roughness influence on contact angle measurements and propose a simple model combining Wenzel and Cassie-Baxter theories with simple 2D roughness profile analysis. The modelling approach is applied to real homogeneous anisotropic surfaces, manufactured on a wide range of engineering materials including aluminium alloy, iron alloy, copper, ceramic, plastic (poly-methylmethacrylate: PMMA) and titanium alloy

Wear resistant multilayer nanocomposite WC1−x/C coating on Ti–6Al–4V titanium alloy

A significant improvement of tribological properties on Ti–6Al–4V has been achieved by developed in this study multilayer treatment method for the titanium alloys. This treatment consists of an intermediate 2 μm thick TiCxNy layer which has been deposited by the reactive arc evaporation onto a diffusion hardened material with interstitial O or N atoms by glow discharge plasma in the atmosphere of Ar+O2 or Ar+N2. Subsequently, an external 0.3 μm thin nanocomposite carbon-based WC1−x/C coating has been deposited by a reactive magnetron sputtering of graphite and tungsten targets. The morphology, microstructure, chemical and phase compositions of the substrate material after treatment and coating deposition have been investigated with use of AFM, SEM, EDX, XRD, 3D profilometry and followed by tribological investigation of wear and friction analysis. An increase of hardness in the diffusion treated near-surface zone of the Ti–6Al–4V substrate has been achieved. In addition, a good adhesion between the intermediate gradient TiCxNy coating and the Ti–6Al–4V substrate as well as with the external nanocomposite coating has been obtained. Significant increase in wear resistance of up to 94% when compared to uncoated Ti–6Al–4V was reported. The proposed multilayer system deposited on the Ti–6Al–4V substrate is a promising method to significantly increase wear resistance of titanium alloys

Roughness Signature of Tribological Contact Calculated by a New Method of Peaks Curvature Radius Estimation on Fractal Surfaces

This paper proposes a new method of roughness peaks curvature radii calculation and its application to tribological contact analysis as characteristic signature of tribological contact. This method is introduced via the classical approach of the calculation of radius of asperity. In fact, the proposed approach provides a generalization to fractal profiles of the Nowicki's method [Nowicki B. Wear Vol.102, p.161-176, 1985] by introducing a fractal concept of curvature radii of surfaces, depending on the observation scale and also numerically depending on horizontal lines intercepted by the studied profile. It is then established the increasing of the dispersion of the measures of that lines with that of the corresponding radii and the dependence of calculated radii on the fractal dimension of the studied curve. Consequently, the notion of peak is mathematically reformulated. The efficiency of the proposed method was tested via simulations of fractal curves such as those described by Brownian motions. A new fractal function allowing the modelling of a large number of physical phenomena was also introduced, and one of the great applications developed in this paper consists in detecting the scale on which the measurement system introduces a smoothing artifact on the data measurement. New methodology is applied to analysis of tribological contact in metal forming process

Dropwise condensation heat transfer process optimisation on superhydrophobic surfaces using a multi-disciplinary approach

Dropwise condensation has superior heat transfer efficiency than filmwise condensation; however condensate evacuation from the surface still remains a significant technological challenge. The process of droplets jumping, against adhesive forces, from a solid surface upon coalescence has been studied using both experimental and Computational Fluid Dynamics (CFD) analysis. Both Lattice Boltzmann (LBM) and Volume of Fluid (VOF) methods have been used to evaluate different kinematic conditions of coalescence inducing a jump velocity. In this paper, an optimisation framework for superhydrophobic surface designs is presented which uses experimentally verified high fidelity CFD analyses to identify optimal combinations of design features which maximise desirable characteristics such as the vertical velocity of the merged jumping droplet from the surface and energy efficiency. A Radial Basis Function (RBF)-based surrogate modelling approach using design of experiment (DOE) technique was used to establish near-optimal initial process parameters around which to focus the study. This multidisciplinary approach allows us to evaluate the jumping phenomenon for superhydrophobic surfaces for which several input parameters may be varied, so as to improve the heat transfer exchange rate on the surface during condensation. Reliable conditions were found to occur for droplets within initial radius range of r=20-40 μm and static contact angle θs~160º. Moreover, the jumping phenomenon was observed for droplets with initial radius of up to 500 μm. Lastly, our study also reveals that a critical contact angle for droplets to jump upon coalescence is θc~140º

Introduction of a fretting-fatigue mapping concept: Development of a dual crack nucleation - crack propagation approach to formalize fretting-fatigue damage

Fretting-fatigue induced by combined localized cyclic contact motion and external bulk fatigue loadings may result in premature and dramatic failure of the contacting components. Depending on fretting and fatigue loading conditions, crack nucleation and possibly crack propagation can be activated. This paper proposes a procedure for estimating these two damage thresholds. The crack nucleation boundary is formalized by applying the Crossland high cycle fatigue criterion taking into account the stress gradient and the ensuing #size##effect#. The prediction of the crack propagation condition is formalized using a short crack arrest description. Applied to a AISI 1034 steel, this methodology allows the development of an original material response fretting-fatigue map, where the different material responses related to crack nucleation, crack arrest and catastrophic failure are established and formalized

Simulation of Drops on Surfaces

This chapter explores ways in which the interactions of liquid drops with solid surfaces can be simulated using numerical methods. Simulations are desirable for a number of reasons, for example:(i) to provide additional insight to complement what can be achieved experimentally,(ii) to explore new (potentially far-fetched) ideas before performing experiments, and hence “steering” experiments efficiently, and (iii) to provide an optimization tool, possibly exploiting formal mathematical/computational optimization methods or ..