Design and construction of a novel tribometer with on-line topography and wear measurement

We present a novel experimental platform that links topographical and material changes with the friction and wear behavior of oil-lubricated metal surfaces. This concept combines state-of-the-art methods for the analysis of the surface topography on the micro- and nano-scale with the online measurement of wear. At the same time, it allows for frictional and lateral force detection. Information on the topography of one of the two surfaces is gathered in-situ with a 3D holography microscope at a maximum frequency of 15 fps and higher resolution images are provided at defined time intervals by an atomic force microscope (AFM). The wear measurement is conducted on-line by means of radio nuclide technique (RNT). The quantitative measurement of the lateral and frictional forces is conducted with a custom-built 3D force sensor. The surfaces can be lubricated with an optically transparent oil or water. The stability and precision of the setup have been tested in a model experiment. The results show that the exact same position can be relocated and examined after each load cycle. Wear and topography measurements were performed with a radioactive labeled iron pin sliding against an iron plate

Microscale study of frictional properties of graphene in ultra high vacuum

We report on the frictional properties of epitaxial graphene on SiC in ultra high vacuum. Measurements have been performed using a microtribometer in the load regime of 0.5 to 1 mN. We observed that a ruby sphere sliding against graphene results in very low friction coefficients ranging from 0.02 to 0.05. The friction and also the stability of the graphene layer is higher than that under similar conditions in ambient conditions. The friction shows a load dependence. Finally it was found that graphene masks the frictional anisotropy which was observed on the SiC surface

Tribology of Wire Arc Spray Coatings under the Influence of Regenerative Fuels

In order to further optimize the efficiency of today’s internal combustion engines, specific coatings are used on functional surfaces to reduce internal engine friction and wear. In the current research project, oxymethylene ether (OME) is discussed because it is CO2 neutral and has a strong soot-reducing effect as a fuel or fuel additive. In some operational regimes of the internal combustion engine a dilution of engine oil by fuel must be assumed. In this paper, the frictional contact between piston ring and cylinder raceway is modelled using a pin-on-disk tribometer and the friction and wear behavior between a diamond-like carbon coating (DLC) and a thermal spray coating is characterized. The wear of the spray layer could be continuously detected by radionuclide technology (RNT). With the aid of photoelectron spectroscopic measurements (XPS), the steel thermal spray coating was chemically analyzed before and after the tribometer tests and the oxidative influence of OME was investigated. In addition, confocal microscopy was used to assess the topographies of the specimens. The measurements showed that the addition of OME to the lubricant reduced the viscosity and load-bearing capacity of the lubricating film, which led to an increase in the coefficient of friction. While almost no wear on the pin could be detected at 10% OME, the first visible material removal occurs at an OME content of 20% and the layer delaminated at 30% OME. The evaluation of the RNT wear tests showed that both the tests with engine oil and with engine oil plus 20% OME achieved very low wear rates. No corrosion of the thermal spray coating could be detected by XPS. Only the proportion of engine oil additives in the friction track increased with increasing OME concentration

Humidity-dependent lubrication of highly loaded contacts by graphite and a structural transition to turbostratic carbon

Graphite represents a promising material for solid lubrication of highly loaded tribological contacts under extreme environmental conditions. At low loads, graphite’s lubricity depends on humidity. The adsorption model explains this by molecular water films on graphite leading to defect passivation and easy sliding of counter bodies. To explore the humidity dependence and validate the adsorption model for high loads, a commercial graphite solid lubricant is studied using microtribometry. Even at 1 GPa contact pressure, a high and low friction regime is observed - depending on humidity. Transmission electron microscopy reveals transformation of the polycrystalline graphite lubricant into turbostratic carbon after high and even after low load (50 MPa) sliding. Quantum molecular dynamics simulations relate high friction and wear to cold welding and shear-induced formation of turbostratic carbon, while low friction originates in molecular water films on surfaces. In this work, a generalized adsorption model including turbostratic carbon formation is suggested

Evolution of the True Contact Area of Laser Textured Tungsten Under Dry Sliding Conditions

Despite the great importance of the real contact area, it is a parameter which, depending on the tribological system, is difficult or impossible to obtain experimentally. In this work, a combination of methods was used to estimate the development of the real contact surface, and the results were compared with the friction coefficient course. The measurements were carried out with a home-built in situ tribometer, which records a 3D image of the surface after each individual friction cycle. A tungsten sample was treated by laser interference with a line-like pattern to produce a deterministic surface. This allowed for more precise tracking of the real contact area when combined with the use of an inert corundum sphere as a counter-body. The real contact area was calculated numerically from the height information obtained using a contact application. Finally, the true contact surface was compared with the parallel-recorded friction values. After a short running-in phase, the friction behavior and the real contact surface showed comparable courses. This indicates that the changes in the real contact area could explain the friction behavior of the laser-patterned sample, and the methodology was proven to be suitable for experimentally estimating the real contact area

Achieving Ultra-Low Friction with Diamond/Metal Systems in Extreme Environments

In the search for achieving ultra-low friction for applications in extreme environments, we evaluate the interfacial processes of diamond/tungsten sliding contacts using an on-line macro-tribometer and a micro-tribometer in an ultra-high vacuum. The coefficient of friction for the tests with the on-line tribometer remained considerably low for unlubricated sliding of tungsten, which correlated well with the relatively low wear rates and low roughness on the wear track throughout the sliding. Ex situ analysis was performed by means of XPS and SEM-FIB in order to better understand the underlying mechanisms of low friction and low-wear sliding. The analysis did not reveal any evidence of tribofilm or transferfilm formation on the counterface, indicating the absence of significant bonding between the diamond and tungsten surfaces, which correlated well with the low-friction values. The minimal adhesive interaction and material transfer can possibly be explained by the low initial roughness values as well as high cohesive bonding energies of the two materials. The appearance of the wear track as well as the relatively higher roughness perpendicular to the sliding indicated that abrasion was the main wear mechanism. In order to elucidate the low friction of this tribocouple, we performed micro-tribological experiments in ultra-high vacuum conditions. The results show that the friction coefficient was reduced significantly in UHV. In addition, subsequently to baking the chamber, the coefficient of friction approached ultra-low values. Based on the results obtained in this study, the diamond/tungsten tribocouple seems promising for tribological interfaces in spacecraft systems, which can improve the durability of the components

Effect of Environment on Microstructure Evolution and Friction of Au–Ni Multilayers

We present results from a systematic investigation of environmental effects on the frictional behavior of Au–Ni multilayer films of varying interlayer spacing. The current results, sliding against ruby spheres in a dry N2 atmosphere, are compared to prior work on the tribological behavior of these materials under ultra-high vacuum (UHV) (Cihan et al. in Sci Rep 9:1–10, 2019). Under both conditions, there is a regime of high friction when the interlayer spacing is large and a regime of low friction when the spacing is small. The low friction regime is associated with a critical grain size below which grain bound-ary sliding is expected to be the dominant mechanism of deformation. A shear-induced alloy formation (60–65 at.% Ni in Au) and a concomitant low friction coefficient was observed with multilayer spacings of 20 nm and lower under UHV. A distinct microstructure was found in dry N2, and is attributed to different interfacial characteristics due to adsorbed species; rather than mixing between Au and Ni layers, only the uppermost Au layers were affected by shearing. These observations are coupled with the friction and wear behavior of multilayer samples sliding under different environments

Gas phase lubrication study with an organic friction modifier

Friction modifier additives play a crucial role in controlling friction and wear of lubricated tribological systems. Model experiments in a controllable atmosphere performed by integrating a tribometer into a system of in situ surface analytical methods in vacuum can give insights into the additives functionality. In this work, thin, well-defined layers of an organic friction modifier (OFM) are adsorbed onto an iron oxide surface by means of an effusion cell immediately before measuring friction and wear. The results show that contrary to the assumption that homogeneous layers are formed, this OFM accumulates in droplets on the surface. Droplet number and radius increase with evaporation time. In friction tests, the smallest friction values are found for a low coverage of droplets. For larger droplets, friction increases due to a capillary neck of additive that forms between the sliding surfaces and is dragged along during the friction test

In Situ Studies on the Competitive Adsorption of Lubricant Additives

A key factor for improvement and innovation in lubricant development is a fundamental understanding of adsorption processes and competing adsorption mechanisms [1]. Many different base oils and additives, as well as various surfaces build a complex interaction space, which has been difficult to map with in-situ methods so far. Here we present a study on the adsorption of corrosion inhibitors, anti-wear additives and friction modifiers from a synthetic and a mineral base oil on metal (Fe2O3) surfaces. In order to obtain quantitative and spatial data during the adsorption process we set up a combined quartz crystal microbalance (QCM-D) and confocal scanning laser microscope (CLSM) [2]. In addition to QCM-D and CLSM, also a UHV-tribometer was used to study the performance of gas phase deposited additives films without environmental interferences. In combination with macroscopic performance tests using a “ball-on-three-plates-tribometer” and corrosion tests, the adsorption, the morphology and the mechanical properties of the additives were correlated with their performance. The multidisciplinary results provide exciting new insights into lubrication fundamentals and reveal so far undescribed phenomes and mechanisms of action. [1] J. Guegan et al. ,Friction Modifier Additives, Synergies and Antagonisms, Tribology Letters 67 (2019) [2] J. Honselmann et al., submitted, 201

Formation of the third bodies of steel sliding against brass under lubricated conditions

This work investigates the formation mechanism of the third bodies for brass under lubricated conditions. Atribometer based on on-line and radio-nuclide technique (RNT) techniques is used to perform the sliding ex-periment of brass versus steel. The microstructure, micro-hardness and chemical composition of the third bodiesare analyzed by mean of the scanning electron microscope (SEM), focused ion beam microscope (FIB), trans-mission electron microscope (TEM), hardness testers and X-ray photoelectron spectroscopy (XPS). The resultsindicate that the contact pairs show good tribological behaviors and the layered third bodies (mechanicallymixed layer (MML), grain refinement zone (GRZ) and plastic deformation zone (PDZ)) are formed on the brasssurface during sliding. The formation mechanism of the third bodies is explored. The MML gradually forms onthe worn surface in the later stage of the test by proceeding of oxidation reactions. Due to the severe plasticdeformation caused by sliding, the interactional dislocation movements and dynamic recrystallization (DRX) lead to the formation of GRZ with nano-scale grains. The PDZ grains lead to the shear deformation by means offriction stress. Moreover, the generation and accumulation of dislocations result in voids in the PDZ