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- Bearing (2)
- Friction (2)
- Gear (2)
- Slip-rolling (2)
- Hardness (1)
- MoDTC (1)
- Residual austenite (1)
- Residual stress (1)
- Running-in (1)
- Steel (1)
- Tribofilm (1)
- Wear (1)
- Wear resistance (1)
- Work hardening (1)
- bismuth (1)
- carbamate (1)
- friction (1)
- slip-rolling (1)
- tribofilm (1)
- wear (1)
The automotive industry places significant importance on downsizing components to achieve greater efficiency. The goal of reducing CO2 emissions has led to the development of lightweight materials that are also able to enhance performance. In light of these aspirations, the aim of this study is to characterize two novel, high-performance steels, as well as a 'classical' gear steel for comparison with each other and currently applied materials. The gear steel underwent carburization and subsequent deep freezing treatments in an attempt to yield discrete sample groups with respect to residual austenite. The high-performance steels were heat treated as recommended by their respective manufacturers, and were not carburized. Elemental analyses were conducted by multiple methods to ensure accurate results. Residual austenite contents of the steels and the depth profiles of residual stresses were determined by X-ray diffraction (XRD). Hardness profiles were taken from the testing surfaces into the material core. The carburization of 20MnCr5 led to higher hardness and the greater concentration of carbon in the carburization zone more representative of a hardened SAE E52100, or 100Cr6/102Cr6, than of a non-carburized 20MnCr5. Residual austenite contents ranging from approximately 6–14 vol% were generated, though effectively providing only two, rather than the desired four discrete sample groups. Residual stresses from machining and carburization were measured directly at the sample surface, and from carburization alone below the surface. The high-performance steels fulfilled manufacturer expectations in terms of elemental content, hardness between 50 and 55 HRC and strongly martensitic microstructure character. Finally, slip-rolling endurance testing (T=+120 °C, 10,000,000 cycles, approximately 19 days in a factory fill engine oil) was carried out on all materials, whereby coefficient of friction distributions during testing and wear coefficients after testing were calculated. Testing was performed up to and including P0Mean=1.94 GPa (P0Max=2.91 GPa, FN=2000 N). Ultimately, the non-carburized high-performance steels showed competitive wear performance and better friction behaviour than the carburized 20MnCr5, which has been attributed to their work hardening capability.
Downsizing in mechanical systems requires effective lubrication strategies to ensure that increased contact stresses do not cause critical material failure during operation. Additionally, eco-toxicological consideration are becoming increasingly important. In this regard, the goal of this investigation is to transfer the running-in phase into the final step of the mechanical finishing process through the targeted pre-conditioning of novel, high toughness steel bearings without thermo-chemical treatments and compare these to conventional, case-hardened Steels. Pre-conditioning involved implementation of the ecologically sustainable, bismuth-based additives to generate chemically reactive tribofilms on slip-rolling contacts by using a formulation with a high concentration of tribofilm forming additive. Generated tribofilms were analyzed by Raman spectroscopy to elucidate their molecular composition and, ultimately, determine the reaction mechanisms of bismuth-based tribofilm formation. Tribofilm-protected samples were subjected to slip-rolling endurance testing in a factory fill engine oil without pre-conditioning additives to determine the influence of pre-condition tribofilms on friction behavior and wear performance. It was observed that pre-conditioned tribofilms from the bismuth-based additives were able to yield lower coefficients of friction (COF) and profilometric wear coefficients than for Steels without pre-conditioning. Moreover, COF values under mixed/boundary conditions approaching and even less than 0.04 were achieved, thereby rivaling DLC-coated alloy equivalents.
The running-in phase of mechanical systems is critical from a tribological standpoint, though poorly understood. Microcracks accelerate material failure and wear during this phase of heightened friction. With this in mind, the ultimate goal of this current work is to transfer the running-in phase into the final step of the mechanical finishing process through the targeted pre-conditioning of novel, high toughness steel bearings without thermo-chemical treatments and compare these to conventional, case-hardened steels. This pre-conditioning involved the targeted implementation of two specific lubricant packages, the first with CaCO3 as the active ingredient and the second with MoDTC as the active ingredient, to generate chemically reactive tribolayers (tribofilms) on twin disk testing rigs. Pre-conditioning was carried out up to 104 load cycles (approximately 25 min). The films generated in pre-conditioning were analyzed by SEM-EDX with Element-Mapping, Raman spectroscopy, and XPS to elucidate their molecular composition and concentration on the sample surfaces. The combination of these methods of analysis gave a clear indication that 104 cycles were sufficient to generate stable chemical tribofilms. CaO and CaCO3 were the main components of the tribofilm from the first lubricant package, while MoS2, MoO2 and MoO3 were the main components from the second lubricant package. Tribofilm-protected samples were then subjected to slip-rolling endurance testing (T=+120 °C, 10,000,000 cycles, approximately 19 days in a factory fill engine oil) to determine any changes in friction behavior or wear performance. Some significant reductions in coefficients of friction at the end of endurance testing were observed, though in certain cases, no definitive improvement was observed. In contrast, very strong reductions in wear were observed across the entire spectrum of materials and testing loads. In some cases, sample surface wear reduction from pre-conditioning via tribofilms reached over 90%. The observed improvements to friction behavior and wear performance are indicative of a technically simple, cost- and energy-efficient pre-conditioning method that may prove to be competitive with existing thermochemical treatments for steel alloys.
The goal of reducing CO2 emissions in the automobile industry has led to the development of increasingly efficient lightweight material solutions that yield enhanced performance. In light of this goal, this current work involves the optimization of the pre-conditioning of novel, high toughness steel bearings without thermo-chemical treatment, with the aim of transferring the running-in phase into the final step of the mechanical finishing process. A case-hardened gear steel and two novel non-case-hardened steels were evaluated.
Die Ausbildung von tribologisch günstigen Grenzschichten ist eine häufig für die Phase des Einlaufs angenommene Modellvorstellung. Solche tribologisch günstige, durch Reibungsvorgänge im Kontaktbereich induzierte Triboschichten, werden in der Fachliteratur auch als sog. Beilby- und Cervovit-Schichten oder auch als Tribomutationen bezeichnet. Durch eine Vorkonditionierung mittels modifizierter Schmierstoffe oder durch Kaltverfestigung kann der Verschleiß in Wälzkontakten signifikant erniedrigt werden. Bislang ausgeblieben ist eine deutliche Reibungsminderung, aber es wurde keine Reibungserhöhung gemessen. Es waren die Ziele, mithilfe geeigneter Schmierstoffadditive in Verbindung mit dem Prozess des Kaltverfestigens durch das „Dichtwalzen“ (unter Hertz’schen Kontaktpressungen oberhalb von Pmax = 3,0 GPa), ohne Vorschädigung, eine metallurgische Veränderung zu erzielen und gleichzeitig durch einen induzierten Tribofilm geschützte Stahloberfläche zu erhalten, sodass thermochemische Behandlungen durch diese Konzepte einzeln oder kombiniert substituiert werden können.