Surface characterization of a real-world cylinder liner subject to deposition from combustion

This paper investigates the effects of combustion product deposition using a cylinder liner taken from a C-segment passenger vehicle run for 105,000 miles. Using a novel methodology of Atomic Force Microscopy and X-ray Photoelectron Spectroscopy the pressure coefficient of boundary shear strength of asperities and the nature of the depositions along the liner is considered to predict the boundary friction of a piston ring pack. Results show that the combustion depositions create localized values of the pressure coefficient of boundary shear strength of asperities at top dead centre, mid-stroke and bottom dead centre, increasing ring pack friction by 50 N in the combustion stroke per engine cycle

Boundary friction characterisation of a used cylinder liner subject to fired engine conditions and surface deposition

In cylinder friction contributes as a primary source of parasitic dissipations in IC engines. For future engines to become more efficient, with enhanced fuel economy and increased power output, accurate prediction of new designs is required over the full lifetime of an engine. The work carried out presents use of a local pressure coefficient of boundary shear strength of asperities value, taking into account the localised effects of surface texture, coating and surface deposition. XPS spectra analysis was also carried out to identify the surface depositions as a result of combustion, not previously taken into account during piston ring pack simulation. Friction was shown by simulation to drop by up to 30% between the compression and combustion stroke as a result of using a carriable coefficient of boundary shear strength of asperities. It was found that piston varnish on the liner corresponded to higher values of the pressure coefficient of boundary shear strength of asperities, therefore showing the importance of using real system components run under representative operating conditions or numerical analyses

Atomic force microscopic measurement of a used cylinder liner for prediction of boundary friction

Accurate simulation performs a crucial role in the design and development of new modern internal combustion engines. In the case of piston rings, simulations are used to effectively predict generated friction and power loss of proposed designs. These are consequences of viscous shear of a thin lubricant film, likewise boundary friction caused by direct interaction of piston rings with the cylinder liner/bore surface. The most commonly used model for determining boundary friction is that of Greenwood and Tripp. The model requires the pressure coefficient of boundary shear strength of asperities from the softer of the contacting surfaces as an input. This parameter needs to be measured. The paper describes the process of measurement using an Atomic Force Microscope (AFM), both for a dry surface and that wetted by the presence of a lubricant layer. For realistic results, the investigated specimen is a used, tested engine cylinder liner where boundary active lubricant additives are bonded to its surface as well as combustion products. This approach is as opposed to the previously reported works using new flat surfaces with base oil or partially formulated lubricants, and has not previously been reported in literature. The results show that for used cylinder liners, the measured boundary shear strength of asperities varies according to location along the stroke. Results are reported for the Top Dead Centre, Mid-stroke and Bottom Dead Centre locations. The measurements are subsequently used with 2D Reynolds Solution for a top compression ring-liner contact, where it is found that accurate localised predictions of generated friction and power loss can be made instead of the usual average value approach reported in literature

Results of measured data from atomic force microscope on ring pack performance

Frictional losses of an IC engine include 40-50% contribution due to piston assembly-liner conjunction. Reduction of friction would improve fuel efficiency and decrease harmful emissions. Therefore, it is important to accurately predict the frictional losses due to viscous shear of a thin lubricant film as well as boundary friction, generated by the direct contact of real rough contiguous surfaces. Greenwood and Tripp model is used to evaluate the contribution due to boundary friction. The model requires the determination of pressure coefficient of boundary shear strength of asperities, ς, which is analogous to the asperity coefficient of friction. This should be determined through measurement, using Atomic Force Microscopy (AFM) in Lateral Force Mode (LFM). The value of ς is dependent on the combination of surface and lubricant as a system. Boundary active lubricant additives adsorb or bond to the surface asperities and affect the value of ς. The value of this coefficient also alters with the evolution of interacting surfaces through the process of wear as well as any degradation of the lubricant. The approach can be used to create a database of such values for different lubricant-surface systems, in particular for piston-liner interactions

Investigation into the effects of topography, surface modification and lubricant rheology on friction of multi-scale surfaces in sliding contacts

Investigation into the effects of topography, surface modification and lubricant rheology on friction of multi-scale surfaces in sliding contact

Electrical field strength in rough infinite line contact elastohydrodynamic conjunctions

Rolling element bearings are required to operate in a variety of use cases that determine voltage potentials will form between the rolling elements and races. When the electrical field strength causes the dielectric breakdown of the intermediary lubricant film electrical discharge can damage the bearing surfaces. To reduce the prevalence and severity of electrical discharge machining an improved understanding of the coupled electrical and mechanical behavior is necessary. This paper aims to improve understanding of the problem through a combined elastohydrodynamic and electrostatic numerical study of charged elastohydrodynamic conjunctions. The results show the effect of amplitude reduction means that for typical surface topographies found in EHL conjunctions the maximum field strength is adequately predicted by the elastohydrodynamic minimum film thickness and potential difference. The paper also indicates the width of the elevated electrical field strength region is dependent on EHL parameters which could have important implications on the magnitude of current density during dielectric breakdown

Asperity level characterization of abrasive wear using atomic force microscopy

Using an atomic force microscope, a nanoscale wear characterization method has been applied to a commercial steel substrate AISI 52100, a common bearing material. Two wear mechanisms were observed by the presented method: atom attrition and elastoplastic ploughing. It is shown that not only friction can be used to classify the difference between these two mechanisms, but also the ‘degree of wear’. Archard's Law of adhesion shows good conformity to experimental data at the nanoscale for the elastoplastic ploughing mechanism. However, there is a distinct discontinuity between the two identified mechanisms of wear and their relation to the load and the removed volume. The length-scale effect of the material's hardness property plays an integral role in the relationship between the ‘degree of wear’ and load. The transition between wear mechanisms is hardness-dependent, as below a load threshold limited plastic deformation in the form of pile up is exhibited. It is revealed that the presented method can be used as a rapid wear characterization technique, but additional work is necessary to project individual asperity interaction observations to macroscale contacts.<br