Dry friction and wear of self-lubricating carbon-nanotube-containing surfaces

The unfavorable environmental conditions of certain tribological systems, such as operation at high temperatures or under vacuum, set the need to replace liquid with solid lubricants. Multi-Wall-Carbon Nanotubes (MWCNTs) have been emphasized as a very effective solid lubricant. The particles have been used to create self-lubricating materials by acting as reinforcement phase in composites or as solid-lubricant coating that works in conjunction with textured surfaces to prevent the removal of particles from the contact. However, both approaches are restricted to some extent. In the case of composites, the solid lubricant concentration is limited so as not to influence the mechanical stability of the final component. For coated surface structures, the textured surfaces can degrade during the experiment. The present study focuses on the combination of these approaches in order to create enhanced self-lubricating surfaces with MWCNTs as the solid lubricant. A custom-made ring-on-block tribometer is used to study the behavior of laser textured MWCNT-coated and MWCNT-reinforced nickel matrix composites under the conditions of unidirectional sliding in conformal contact. It is shown that the combination of both approaches allows for a maximum 4-fold reduction in friction and a 115-fold reduction in wear rate compared to the reference. Additionally, the lubrication mechanism of the MWCNTs is investigated in more detail and a structural degradation model of the mechanically stressed MWCNTs is proposed. Our results highlight the integrated solution as a suitable approach for self-lubricating surfaces subjected to unidirectional sliding

Interplay between microstructural evolution and tribo-chemistry during dry sliding of metals

Understanding the microstructural and tribo-chemical processes during tribological loading is of utmost importance to further improve the tribological behavior of metals. In this study, the friction, wear and tribo-chemical behavior of Ni with different initial microstructures (nanocrystalline, bi-modal, coarse-grained) is investigated under dry sliding conditions. In particular, the interplay be-tween frictional response, microstructural evolution and tribo-oxidation is considered. Friction tests are carried out using ball-on-disk experiments with alumina balls as counter-bodies, varying the load between 1 and 5 N. The microstructural evolution as well as the chemical reactions beneath the samples’ surface is investigated by means of cross-sections. The samples with finer microstructures show a faster run-in and lower maximum values of the coefficient of friction (COF) which can be attributed to higher oxidation kinetics and a higher hardness. It is observed that with increasing sliding cycles, a stable oxide layer is formed. Furthermore, initially coarse-grained samples show grain refinement, whereas initially finer microstructures undergo grain coarsening converging towards the same superficial grain size after 2,000 sliding cycles. Consequently, the experimental evidence supports that, irrespective of the initial microstructure, after a certain deformation almost identical steady-state COF values for all samples are achieved

Ultrasonic assisted polyol-reduction of HAuCl4 for nanoparticle decoration of multiwall carbon nanotubes

The decoration of carbon nanotubes with metallic nanoparticles has been extensively studied for different systems. Despite the fact that several routes are available for the production of these heterostructures, their complexity and large amount of different reagents severely hinder their applicability. In this study, we propose an alternative route based on an ultrasonic assisted polyol reduction, which requires lower temperatures and amount of reagents when compared to traditional methodologies. Furthermore, the used solvent (ethylene glycol) is more environmentally friendly than other common reagents, resulting in a less aggressive process. Weobserved that the proposed route provides the possibility of straightforwardly tune the final nanoparticle size by controlling simple parameters such as exposure time and relative reagent concentrations. Moreover, the influence of the bath temperature has been studied, finding an upper limit of 50 °Cfor the proposed methodology

Tribological behavior of self-lubricating carbon nanoparticle reinforced metal matrix composites

The present study focuses on investigating the dominant friction and wear mechanisms in case of dry sliding of carbon nanoparticle reinforced nickel matrix composites under elastic and elasto-plastic contact conditions. For this purpose, multi-wall carbon nanotubes (CNT), onion-like carbon (OLC) and nanodiamonds (nD) were chosen to represent a large variety of carbon nanoparticles as they can be systematically distinguished regarding their carbon hybridization state (sp 2 vs. sp3) as well as their morphology and size (“0D” vs. “1D”). Contact simulations based on the Greenwood-Williamson model are conducted in order to calculate the required contact loads. Friction and wear analysis is supported by complementary characterization techniques, including scanning electron microscopy, transmission electron microscopy, energy dispersive spectroscopy, Raman spectroscopy, light microscopy as well as laser scanning microscopy. It is found, that only CNT provide efficient lubrication as reinforcement phase in composites, presenting different lubrication mechanisms for the tested contact conditions. The high aspect ratio of CNT is found to be essential for the lubrication mechanisms, allowing the particles to be dragged into the direct tribological contact. The lubrication effect increases with increasing volume content of CNT, reaching a maximum steady state frictional reduction of 50% compared to the unreinforced nickel reference

Influence of Surface Roughness on the Lubrication Effect of Carbon Nanoparticle-Coated Steel Surfaces

In the present study, a systematic evaluation of the influence of the surface roughness on the lubrication activity of multiwall carbon nanotubes (MWCNT) and onion-like carbon (OLC) is performed. MWCNT and OLC are chosen as they both present an sp2-hybridization of carbon atoms, show a similar layered atomic structure, and exhibit the potential to roll on top of a surface. However, their morphology (size and aspect ratio) clearly differs, allowing for a methodical study of these differences on the lubrication effect on systematically varied surface roughness. Stainless steel platelets with different surface finishing were produced and coated by electrophoretic deposition with OLC or MWCNT. The frictional behavior is recorded using a ball-on-disk tribometer, and the resulting wear tracks are analyzed by scanning electron microscopy in order to reveal the acting tribological mechanisms. It is found that the lubrication mechanism of both types of particles is traced back to a mixture between a rolling motion on the surfaces and particle degradation, including the formation of nanocrystalline graphitic layers. This investigation further highlights that choosing the suitable surface finish for a tribological application is crucial for achieving beneficial tribological effects of carbon nanoparticle lubricated surfaces

Influence of the Reinforcement Distribution and Interface on the Electronic Transport Properties of MWCNT-Reinforced Metal Matrix Composites

The transition towards an electricity-driven world is testing electrical contact materials to their limits. Specifically, new alternatives are needed where composites that sacrificed conductivity in exchange for reduced weldability and higher heat dissipation sufficed. Carbon nanotubes (CNT) have the potential to close the gap as ideal fillers due to their outstanding intrinsic properties, pushing the application limits further. However, the reported electrical conductivity measurements showed no clear tendency. In the present study we attempt to shed some light on this matter by focusing on the causes behind those results. We observed that the addition of 1 wt. % CNT improves the conductivity of nickel, followed by a drop for higher concentrations, measured by 4-point probe testing. Six nanotube orientation models describing different CNT arrangements were contrasted to the experimental data. Corrected values for nickel and CNT resistivities effectively place that of the composites close to the models, providing indications of a preferential orientation. We conclude that, in contrast to what is widely reported, the main contributing factors to the resistivity are inter-tube coupling, porosity and interfacial scattering, whereas clustering marginally influences the behaviour

Secondary carbides in high chromium cast irons: An alternative approach to their morphological and spatial distribution characterization

Secondary carbides precipitated in high chromium cast irons during thermal treatments were characterized by means of different characterization techniques, including scanning electron microscopy, energy dispersive X-ray spectroscopy, electron backscattered diffraction and a combination of chemical etching with confocal scanning laser microscopy. This set of techniques provides a full morphological, chemical and crystallographic description of the analysed phases. This work evaluated different methods for optimizing the image acquisition for a further image analysis (IA) based on the threshold binarization. Finally, the carbide size, distribution and morphology were determined after IA of the images acquired by aforementioned characterization techniques. Although the different techniques report some dispersion in the value for the average particle size, the particle inter-spacing and aspect ratio meet within the error value. The proposed characterization methodology provides statistically reliable data for a further evaluation of related physical properties in composites

Microstructural and Chemical Characterization of the Tribolayer Formation in Highly Loaded Cylindrical Roller Thrust Bearings

Zinc dithiophosphates (ZDDP) have been widely applied in automobile industry for over 70 years as a lubricant additive for wear protection. Tribolayers have been described as blue- and brown-colored layers on surfaces observed by microscopical observation or even bare eye presumably as a consequence of layer thickness or chemical composition. However, the reaction pathways of ZDDP tribolayers are still not yet fully understood. In the present study, the difference between the blue- and brown-colored tribolayers has been revealed by high resolution methods in cylindrical roller thrust bearings at relatively high contact pressures of around 1.92 GPa. After running a FE8 standard bearing test with a normal load of 80 kN and a temperature of 60 °C, said tribolayers could be identified on the bearing surfaces. By using Raman spectroscopy, it could be shown that the blue-colored layers are enriched by FeS and ZnS whereas the brown-colored layers show a significant amount of Fe3O4. This is an interesting finding as it clearly shows a correlation between the color appearance of the films and the chemical composition besides potential film thickness variations. Finally, transmission electron microscopy verified the amorphous nature of the formed tribolayer which is in a good agreement with literature

Influence of Surface Design on the Solid Lubricity of Carbon Nanotubes-Coated Steel Surfaces

Topographically designed surfaces are able to store solid lubricants, preventing their removal out of the tribological contact and thus significantly prolonging the lubrication lifetime of a surface. The present study provides a systematic evaluation of the influence of surface structure design on the solid lubrication effect of multi-walled carbon nanotubes (MWCNT) coated steel surfaces. For this purpose, direct laser writing using a femtosecond pulsed laser system is deployed to create surface structures, which are subsequently coated with MWCNT by electrophoretic deposition. The structural depth or aspect ratio of the structures and thus the lubricant storage volume of the solid lubricant is varied. The frictional behavior of the surfaces is recorded using a ball-on-disk tribometer and the surfaces are thoroughly characterized by complementary characterization techniques. Efficient lubrication is achieved for all MWCNT-coated surfaces. However, and in contrast to what would be expected, it is shown that deeper structures with larger lubricant storage volume do not lead to an extended lubrication lifetime and behave almost equally to the coated unstructured surfaces. This can be attributed, among other things, to differences in the final surface roughness of the structures and the slope steepness of the structures, which prevent efficient lubricant supply into the contact

High Chromium Cast Irons: Destabilized-Subcritical Secondary Carbide Precipitation and Its Effect on Hardness and Wear Properties

This work evaluates the effect of a destabilization treatment combined with a subcritical diffusion (SCD) and a subsequent quenching (Q) steps on precipitation of secondary carbides and their influence on the wear properties of HCCI (16%Cr). The destabilization of the austenite at high temperature leads to a final microstructure composed of eutectic and secondary carbides, with an M7C3 nature, embedded in a martensitic matrix. An improved wear resistance was observed in the SCD + Q samples in comparison with the Q one, which was attributed to the size of secondary carbides