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The slip-rolling resistances of hard and stiff thin films under high Hertzian contact pressures can be improved by optimizing the 'coating/substrate systems'. It is known from former investigations that the so-called 'egg-shell' effect is no general hindrance for high slip-rolling resistance of thin hard coatings. The coating stability depends more on specific deposition process and coating/substrate interface design. In this article it is experimentally shown, that pure amorphous carbon thin films with hardness between 15 and 63 GPa can be slip-rolling resistant several million load cycles under a maximum Hertzian contact pressures of up to 3.0 GPa. Whereas all coatings were stable up to 10 million load cycles in paraffin oil at room temperature, reduced coating lifetime was found in SAE 0W-30 engine oil at 120°C. It was shown how the coating hardness and the initial coating surface roughness influence the running-in process and coating lifetime. No clear correlation between coating hardness and coating lifetime could be observed, but friction coefficients seem to be reduced with higher coating hardness. Very low friction down to ~0.03 in unmodified engine oils was found for the hardest ta-C film.------------------------------------------------------------------------------------------------------------------------------------------------
Die Wälzbeständigkeit von harten und steifen Dünnschichten unter hohen Hertzschen Kontaktpressungen kann durch die Optimierung des 'Beschichtung/Substrat Systems' deutlich verbessert werden. Aus vorangegangenen Untersuchungen ist bekannt, dass der so genannte 'Eierschaleneffekt' kein generelles Hindernis für eine hohe Wälzbeständigkeit für harte Dünnschichten darstellen muss. Die Stabilität der Beschichtungen hängt vielmehr von dem spezifischen Prozessparametern und dem Schicht/Substrat Grenzflächendesign ab. In diesem Artikel wird experimentell nachgewiesen, dass reine amorphe Kohlenstoffdünnschichten mit Härtewerten zwischen 15 und 63 GPa für mehrere Millionen Lastzyklen unter maximalen Hertzschen Kontaktpressungen bis 3.0 GPa überrollbeständig sein können. Während alle Beschichtungen bis 10 Millionen Lastzyklen in Paraffinöl bei Raumtemperatur keine Defekte aufweisen wurde unter Verwendung eines SAE 0W-30 Motorenöls bei 120°C eine Verringerung der Überrollbeständigkeit nachgewiesen. Es wurde nachgewiesen, wie die Schichthärte und ursprüngliche Oberflächenrauheit der Beschichtung den Einlaufprozess und die Lebensdauer beeinflussen. Es konnte keine offensichtliche Korrelation zwischen Schichthärte und Lebensdauer festgestellt werden, allerdings wurde eine scheinbare Reduktion des Reibwertes mit steigender Schichthärte beobachtet werden. Dabei zeigte die härteste ta-C Schicht unter Verwendung des Motorenöls sehr geringe Reibwerte mit ~0.03.
In order to reduce experimental effort, tribological tests are performed for coating selection, simulating the friction, wear and scuffing behaviour between the piston ring and cylinder liner, as well as lubricant evaluation. The creation of test standards in piston ring/cylinder liner simulation is discussed. PVD coatings, HVOF coatings and nitriding treatments have been applied to piston rings as alternative for chromium coatings. CrN/TiN coating seems very effective for increasing the wear and scuffing resistance. Biodegradable engine oils based on esters and polyglycols reduce friction and exceed the wear resistance of reference engine oils based on hydrocarbons for the new generation engines with high cylinder pressures.
Testing friction and wear of the tribosystem piston ring and cylinder liner outside of engines
(2008)
An OEM-driven working group started in January 2004 to elaborate the philosophies, concepts and test procedures for testing piston ring and cylinder liner materials as well as engine oils outside of engines using the SRV (abbreviation for German: Schwingung, Reibung, Verschleiß; in English: Oscillation, Friction, Wear) test equipment. The different SRV test philosophies in use by OEMs are compiled. The working group focuses on (i) ASTM fuel economy sequence by ageing oils; (ii) friction and wear in the top-dead-centre region under mixed/boundary lubrication; (iii) extreme pressure load under mixed/boundary lubrication; and (iv) hydrodynamic friction. Tribological test results and precision data are presented.
A novel tribometer has been designed using commercially available components for sliding motion at 40kHz with amplitude between 2.5 and 5µm. The tribometer is equipped with means to measure amplitude, frequency, power required to keep the sample in motion and load applied. The effective motion between the two contacting bodies is monitored. These data are used to evaluate the coefficient of friction. The wear rate was determined after the tests. The set-up was tested using novel, non-commercial substrates such as AlFeCrTi-alloys and tungsten carbide-based coatings as well as Magnéli-type coatings (Tin-2Cr2O2n-1 and TinO2n-1). This paper presents the principle of the ultra-high frequency tribometer and first tribological quantities of materials and coatings tested.
The use of alternative base oils, like esters or polyglycols, with more intrinsic properties for the lubrication of automobile engines has a potential for ecological and technical advantages. Being in competition with hydrocarbon-based formulations, detailed knowledge of several thermophysical and viscometric properties as well as tribological properties over a large temperature range are required (mapping). The tested polymer-free polyglycols and ester-based formulations displayed no visible tribological weaknesses regarding wear resistance and EP-behavior as well as offering significant advantages in order to meet metal- and ash-free and bio-no-tox criteria. Especially the formulated polyglycols without friction modifiers also showed an intrinsic retention of low coefficients of friction and a hydrodynamic film forming behavior comparable to hydrocarbon-based factory-fill oils. The wear resistance and EP-behavior of low-additivated polyglycols, but also of esters, can be enhanced by means of triboactive materials. Lubricious oxides or triboactive materials and polar base oils, or a combination thereof, may substitute the EP and AW properties realized by the additives, thus enabling long drains and responding to eco-tox or bio-no-tox requirements as well as restrictions from the chemical box.
Zero wear (Null Verschleiß)
(2013)