Influence of roughness on ZDDP tribofilm formation in boundary lubricated fretting

Influence of initial surface topography on tribofilm formation in ZDDP lubricated contact was analysed. A small displacement fretting tests with sinusoidal motion were carried out in classical sphere/plane configuration. A range of surfaces with different initial roughness were prepared by milling and grinding processes. Tests were carried out using variable displacement method where amplitude of imposed displacement was gradually increased after every 1000 cycles from 2 to 30 µm. The surfaces after tribological tests were measured by interferometric profiler. Main findings confirm that initial roughness has a significant influence on antiwear tribofilm formation in boundary lubricated contact. Tribofilm form faster and require less energy to activate in case of rough surface obtained by milling process than in case of smooth grinded surface. However, in contact lubricated by ZDDP additive a significant transfer of material occurred from plane to sphere specimen

Energy Efficiency Optimization of Superhydrophobic Surfaces for Enhanced Condensation Heat Transfer

The process of droplets jumping, against adhesive forces, from a solid surface upon coalescence has been studied in detail using experimentally-validated CFD modelling. Both Lattice Boltzmann and Volume of Fluid methods have been used to evaluate different kinematic conditions of coalescence inducing a jump velocity. Design of experiment techniques were 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 super-hydrophobic 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. Our study also shows that a critical contact angle for droplets to jump upon coalescence is θc~140º

Adaptive Gaussian process emulators for efficient reliability analysis

This paper presents an approximation method for performing efficient reliability analysis with complex computer models. The computational cost of industrial-scale models can cause problems when performing sampling-based reliability analysis. This is due to the fact that the failure modes of the system typically occupy a small region of the performance space and thus require relatively large sample sizes to accurately estimate their characteristics. The sequential sampling method proposed in this article, combines Gaussian process-based optimisation and subset simulation. Gaussian process emulators construct a statistical approximation to the output of the original code, which is both affordable to use and has its own measure of predictive uncertainty. Subset simulation is used as an integral part of the algorithm to efficiently populate those regions of the surrogate which are likely to lead to the performance function exceeding a predefined critical threshold. The emulator itself is used to inform decisions about efficiently using the original code to augment its predictions. The iterative nature of the method ensures that an arbitrarily accurate approximation of the failure region is developed at a reasonable computational cost. The presented method is applied to an industrial model of a biodiesel filter

Mixing and internal dynamics of droplets impacting and coalescing on a solid surface.

The coalescence and mixing of a sessile and an impacting liquid droplet on a solid surface are studied experimentally and numerically in terms of lateral separation and droplet speed. Two droplet generators are used to produce differently colored droplets. Two high-speed imaging systems are used to investigate the impact and coalescence of the droplets in color from a side view with a simultaneous gray-scale view from below. Millimeter-sized droplets were used with dynamical conditions, based on the Reynolds and Weber numbers, relevant to microfluidics and commercial inkjet printing. Experimental measurements of advancing and receding static contact angles are used to calibrate a contact angle hysteresis model within a lattice Boltzmann framework, which is shown to capture the observed dynamics qualitatively and the final droplet configuration quantitatively. Our results show that no detectable mixing occurs during impact and coalescence of similar-sized droplets, but when the sessile droplet is sufficiently larger than the impacting droplet vortex ring generation can be observed. Finally we show how a gradient of wettability on the substrate can potentially enhance mixing.This work was supported by the Engineering and Physical Sciences Research Council (Grant No. EP/H018913/, Innovation in industrial inkjet technology) and the KACST-Cambridge Research Centre.This is the accepted version of the original article published in Physical Review E and available online here: http://link.aps.org/doi/10.1103/PhysRevE.88.023023

Microstructure, nano-mechanical characterization, and fretting wear behavior of plasma surface Cr-Nb alloying on γ-TiAl

In this study, surface Cr-Nb alloying was realized on γ-TiAl using double glow plasma hollow cathode discharge technique. An inter-diffusion layer was generated under the surface, composed of Cr2Nb intermetallic compounds. After Cr-Nb alloying, the surface nanohardness of γ-TiAl increased from 5.65 to 11.61 GPa. The surface H/E and H3/E2 increased from 3.37 to 5.98 and from 0.64 to 4.15, respectively. Cr-Nb alloying and its effect on fretting wear were investigated. The surface treatment resulted in improved plastic deformation and fretting wear resistance of γ-TiAl. The fretting wear test showed that an average friction coefficient of γ-TiAl against Si3N4 ball was significantly decreased after Cr-Nb alloying. The fluctuation of friction coefficient during running-in stage was significantly improved. The friction behavior of both γ-TiAl before and after Cr-Nb alloying could be divided into distinctive stages including formation of debris, flaking, formation of crack, and delamination. It was observed that the high hardness, resistance to plastic deformation, and fatigue resistance of γ-TiAl after Cr-Nb alloying could inhibit the formation of debris and delamination during friction test. The fretting wear scar area and the maximum wear scar depth were decreased, indicating that the wear resistance of γ-TiAl has been greatly improved after Cr-Nb alloying. The results indicated that plasma surface Cr-Nb alloying is an effective way for improving the fretting wear resistance of γ-TiAl in aviation area

Analysis of surface roughness morphology with TRIZ methodology in automotive electrical contacts: Design against third body fretting-corrosion

Electrical connectors for motor vehicles are essential for the safe and efficient operation of a vehicle. However, their durability is limited by fretting induced corrosion. This type of surface damage is observed between two interconnected surfaces exposed to vibration and temperature variations. Such conditions occur during normal vehicle operation and cause two parts of an electrical contact to move at high frequency and with a small amplitude of movement relative to each other. This damages both surfaces, creates wear particles and then oxidizes them in the air. This causes an oxide layer to form at the interface, isolating the two surfaces and increasing the electrical resistance, resulting in contact failure. This study shows how the service life of electrical contacts can be extended by a surface design approach that controls the metal interface and ensures low contact resistance. The approach combines surface morphology with the progressive process of interfacial oxidation. A strong relationship between surface roughness and electrical contact resistance was observed and is elucidated in this study. Theory of Inventive Problems Solving (TRIZ) was used to identify surface texturing as a viable option to increase durability of automotive electrical connectors

Heat Transfer Enhancement by Perforated and Louvred Fin Heat Exchangers

Multi-tube multi-fin heat exchangers are extensively used in various industries. In the current work, detailed experimental investigations were carried out to establish the flow/heat transfer characteristics in three distinct heat exchanger geometries. A novel perforated plain fin design was developed, and its performance was evaluated against standard plain and louvred fins designs. Experimental setups were designed, and the tests were carefully carried out which enabled quantification of the heat transfer and pressure drop characteristics. In the experiments the average velocity of air was varied in the range of 0.7 m/s to 4 m/s corresponding to Reynolds numbers of 600 to 2650. The water side flow rates in the tubes were kept at 0.12, 0.18, 0.24, 0.3, and 0.36 m3/h corresponding to Reynolds numbers between 6000 and 30,000. It was found that the louvred fins produced the highest heat transfer rate due to the availability of higher surface area, but it also produced the highest pressure drops. Conversely, while the new perforated design produced a slightly higher pressure drop than the plain fin design, it gave a higher value of heat transfer rate than the plain fin especially at the lower liquid flow rates. Specifically, the louvred fin gave consistently high pressure drops, up to 3 to 4 times more than the plain and perforated models at 4 m/s air flow, however, the heat transfer enhancement was only about 11% and 13% over the perforated and plain fin models, respectively. The mean heat transfer rate and pressure drops were used to calculate the Colburn and Fanning friction factors. Two novel semiempirical relationships were derived for the heat exchanger’s Fanning and Colburn factors as functions of the non-dimensional fin surface area and the Reynolds number. It was demonstrated that the Colburn and Fanning factors were predicted by the new correlations to within ±15% of the experiments

Refinement of the Magnesium–Aluminium Alloy Microstructure with Zirconium

The magnesium–aluminium alloy AZ91 was inoculated with zirconium to refine the microstructure. Six different concentrations of zirconium content were tested, ranging from 0.1 to 0.6 wt %, and compared to the baseline AZ91 alloy without modification. Melted metal was poured into a preheated ceramic mould and the temperature was measured and recorded during the solidification. The derivative and thermal analysis (DTA) was performed to compare the crystallisation dynamics. Formed microstructure was analysed using an optical microscope, scanning electron microscopy (SEM-EDX) and energy dispersive X-ray spectrometry (XRD). The chemical composition was measured using an arc spectrometer. The time of solidification was shortened for the samples with a concentration of zirconium 0.3 wt % and the microstructure was refined. The level of grain refinement remained below 10% and the grain shape was changed to more spherical shapes. Both the primary magnesium and eutectic phases were modified. However, at a low concentration of zirconium (0.1 and 0.2 wt %), the primary grain size was increased. Therefore, the optimal zirconium concentration was 0.3 wt %. Larger concentrations (0.4 to 0.6 wt %) did not provide any additional benefit. Theoretical analysis showed that some Al3Zr intermetallic phases can form, which was confirmed on the derivate curve of the thermal analysis, and SEM-EDS and XRD analyse