Impact of corrosion on fretting damage of electrical contacts

Electrical contacts are used in a large number of industrial applications, this includes all sorts of modern transportation: airplanes, trains and automobiles. Mechanical assemblies are subjected to vibrations and micro-displacements between mating surfaces are observed leading to fretting wear. Mechanical degradation can additionally be accelerated by a corrosive factor caused by variable humidity, temperature and corrosive gas attack. Fretting-corrosion leads to an increase of contact resistance or intermittent contact resistance faults as corrosion products change the nature of the interface primary through a range of film formation processes. In this work the impact of a corrosion product film formed on copper and gold surfaces on the electrical contact fretting behavior is shown. It has been observed that modification of the interface by the formation of the surface layer can surprisingly lead to increase of the electrical contact durability

Impact of variable loading conditions on fretting wear

Fretting is considered as a specific type of reciprocating sliding. It is defined as a small displacement amplitude oscillatory motion between two solids in contact, usually induced by vibrations. Depending on the loading conditions (displacement amplitudes, normal loading), fretting causes damage by surface fatigue and wear induced by debris formation. To prevent such damage, numerous hard coatings have been developed which improve the wear resistance of contacts. However, one difficulty is to estimate how long it will be before the coating wears through. Studies have been conducted to analyze the effect of displacement amplitude, normal force or ambient atmosphere, but usually under constant loading conditions. Such a situation is far from real operating components, where elements are subjected to variable loadings implying variable displacement amplitudes. To predict the durability of a coating under variable fretting displacements, wear depth is quantified as a function of the maximum accumulated dissipated energy density by derivation from a global energy wear approach. This model is compared to TiC vs. alumina fretting experiments. Very good correlation is observed between the prediction and the wear depth, independently of the applied variable amplitude sequences. An equivalent “Miner-Energy” wear model is introduced which permits the durability of the coating to be estimated

Development of a Wöhler-like approach to quantify the Ti(CxNy) coatings durability under oscillating sliding conditions

The selection of a proper material for the particular engineering application is a complex problem, as different materials offer unique properties and it is not possible to gather all useful characteristics in a single one. Hence, employment of different surface treatment processes is a widely used alternative solution. In many industrial applications, coating failure may be conducive to catastrophic consequences. Thus, to prevent the component damage it is essential to establish the coating endurance and indicate the safe running time of coated system. To this study PVD TiC, TiN and TiCN hard coatings have been selected and tested against polycrystalline alumina smooth ball. The series of fretting tests with reciprocating sliding at the frequency 5Hz have been carried out under 50-150N normal loads and under wide rage of constant as well as variable displacement amplitudes from 50µm to 200µm at a constant value of relative humidity of 50% at 296K temperature. To quantify the loss of material a dissipated energy approach has been applied where the wear depth evolution is referred to the cumulative density of friction work dissipated during the test. Different dominant damage mechanisms have been indicated for the investigated hard coatings, which is debris formation and ejection in case of TiC coating and progressive wear accelerated by cracking phenomena in case of TiN and TiCN coatings. Energy-Wöhler wear chart has been introduced, in which the critical 1 dissipated energy density corresponds to the moment when the substrate is reached after a given number of fretting cycles. Two different methods to determine the critical dissipated energy density are introduced and compared. The Energy-Wöhler approach has been employed not only to compare the global endurance of the investigated systems but also to compare the intrinsic wear properties of the coatings. It has been shown that the fretting wear process is accelerated by the stress-controlled spalling phenomenon below a critical residual thickness and a severe decohesion mechanism is activated. Finally the applicability of the investigated method to other coated systems subjected to wear under sliding conditions is discussed and analyzed. The perspectives of this new approach are elucidated

Synovial joint lubrication – does nature teach more effective engineering lubrication strategies?

Nature shows numerous examples of systems which show energy efficiency, elegance in their design and optimum use of materials. Biomimetics is an emerging field of research in engineering and successes have been documented in the diverse fields of robotics, mechanics, materials engineering and many more. To date little biomimetics research has been directed towards tribology in terms of transferring technologies from biological systems into engineering applications. The potential for biomimicry has been recognised in terms of replicating natural lubricants but this system reviews the potential for mimicking the synovial joint as an efficient and durable tribological system for potential engineering systems. The use of materials and the integration of materials technology and fluid/surface interactions are central to the discussion

Fretting wear of TiN PVD coating under variable relative humidity conditions – development of a “composite” wear law

Fretting is defined as a small oscillatory displacement between two contacting bodies. The interface is damaged by debris generation and its ejection from the contact area. The application of hard coatings is an established solution to protect against fretting wear. For this study the TiN hard coating manufactured by a PVD method has been selected, and tested against a polycrystalline alumina smooth ball. A fretting test programme has been carried out at a frequency of 5 Hz, 100 N normal load, 100 μm displacement amplitude and at five values of relative humidity: 10, 30, 50, 70 and 90% at a temperature of 296 K. The intensity of the wear process is shown to be significantly dependent on the environmental conditions. A dissipated energy approach has been employed in this study to quantify wear rates of the hard coating. The approach predicts wear kinetics under constant medium relative humidity in a stable manner. It has been shown that an increase of relative humidity promotes the formation of hydrate structures at the interface and modifies the third body rheology. This phenomenon has been characterised by the evolution of wear kinetics associated with a significant variation of the corresponding energy wear coefficient. Hence, a ‘composite’ wear law, integrating the energy wear coefficient as a function of relative humidity, is introduced. It permits a prediction of wear under variable relative humidity conditions from 10 to 90% within a single fretting test. The stability of this approach is demonstrated by comparing various variable relative humidity sequences

Providing adhesion for a miniture mobile intra-abdominal device based on biomimetic principles

This paper investigates the surface adhesion characteristics required for a miniature mobile device to move around the abdominal cavity. Such a device must be capable of adhering to the tissue lining and move freely across the upper surface of the insufflated abdomen. Accordingly, the potential of utilising bioinspired solutions to facilitate wet adhesion is assessed

Factors affecting the citations of papers in tribology journals

The citations count is flawed but it still the most common way of measuring the academic impact used by scholarly journals (Impact Factor), individual researchers (h-index) and funding agencies (a proxy for quality of research). Individual papers should attract citations depending upon the importance and usefulness of the results presented. However, large enough data sets reveal that there are parameters independent of individual papers' quality that can determine an average citation rate. Here, we examine papers (4756 in total) published in six selected tribology journals in a six-year window between January 2010 and December 2015. Citations were retrieved from the Web of Science and compared with their (1) manuscript length, (2) number of authors, (3) number of affiliated institutions, (4) number of international co-authors, (5) number of cited references, (6) number of words in the title, and (7) mode of publication (open versus paid access). The results revealed that citations received by papers published in tribology journals are affected by all of these parameters. This is a significant finding for authors wishing to increase the impact of their research. This knowledge can be used effectively at the manuscript planning and writing stages to support scientific merit. We suggest that the significance of parameters not directly related to the quality of a scholarly paper will become more critical with the rise of alternative ways of measuring impact including novel generation of paper metrics (e.g., Eigenfactor, SJR), social mentions, and viral outreach

Nano-indentation mapping of fretting-induced surface layers

Tribologically modified surface layer results from the energy dissipated in the frictional contact area. This layer usually has a different elastic modulus and hardness from the substrate, and its structure corresponds to the intermediate stage between a material of the first-body and debris of the third-body. Even though, the existence of the tribologically transformed structure in the fretting contact has been well proven, the formation and mechanical transformation mechanisms are still not clear. Hence, in this paper, evolution of mechanical properties of four metallic materials (titanium alloy, stainless steel, carbon steel, copper alloy) induced by fretting was investigated using nano-indentation mapping of the fretting wear scars. It was shown that the tribologically transformed structure formed very quickly within the initial fretting cycles, and its mechanical properties remained almost constant during the entire test duration for tested materials. However, it was observed that all materials responded differently to the frictional energy, exhibiting particular rate of change of the H/E ratio before and after the fretting experiment. Modified XRD technique was used to probe the friction induced changes within the small spots of the fretting scars, and revealed distinctive structural modifications within the transformed layers. The approach proposed in this study can be used to inform the predictive wear models, by providing information about the evolution of the mechanical properties of the tribo-system with time