Counter Surface Research Articles

A Fast Numerical Approach for Investigating Adhesion Strength in Fibrillar Structures: Impact of Buckling and Roughness

This study presents a numerical investigation into the adhesion strength of micro fibrillar structures, incorporating statistical analysis and the effects of excessive pre–load leading to fibril buckling. Fibrils are modeled as soft cylinders using the Euler–Bernoulli beam theory, with buckling conditions described across three distinct states, each affecting the adhesive properties of the fibrils. Iterative simulations analyze how adhesion strength varies with pre–load, roughness, number of fibrils, and the work of adhesion. Roughness is modeled both in fibril heights and in the texture of a rigid counter surface, following a normal distribution with a single variance parameter. Results indicate that roughness and pre–load significantly influence adhesion strength, with excessive pre–load causing substantial buckling and a dramatic reduction in adhesion. This study also finds that adhesion strength decreases exponentially with increasing roughness, in line with theoretical expectations. The findings highlight the importance of buckling and roughness parameters in determining adhesion strength. This study offers valuable insights into the complex adhesive interactions of fibrillar structures, offering a scalable solution for rapid assessment of adhesion in various rough surface and loading scenarios.

Predicting Low Sliding Friction in Al-Steel Reciprocating Sliding Experiment after a Controlled Grinding of the Steel Counterface

The aim of this study was to identify the areal surface parameters that correlated with lowering of sliding friction. Different ground surfaces were created on stainless steel and the lubricated sliding friction generated at the contact interface with a flat-faced aluminum pin was studied. The frictional force encountered is an order of magnitude lower for a P1200-finished surface than the other ground surfaces. Using 3D surface profilometry, a unique surface parameter ratio “Spk/Sk” was found to predict the frictional performance of these surfaces. When this surface parameter ratio was less than 1, average sliding friction was close to 0.1. When this ratio was greater than 1, the coefficient was an order of magnitude lower. Using energy dispersive spectrometry, such surfaces after wear showed the presence of a uniform dispersed layer of iron oxide on the surface of the pin. This was absent on the surfaces having high friction, indicating the role of the steel counter surface in building this beneficial transfer layer. Scanning electron microscopy provided topography images to visualize the surface wear. The motivation for the authors was to use a commercially scaled process like precision grinding for the surface modifications on stainless steel.

Wear Performance Evaluation of Polymer Overlays on Engine Bearings.

Modern engine bearing materials encounter the challenge of functioning under conditions of mixed lubrication, low viscosity oils, downsizing, start-stop engines, potentially leading to metal-to-metal contact and, subsequently, premature bearing failure. In this work, two types of polymer overlays were applied to the bearing surface to compensate for extreme conditions, such as excessive loads and mixed lubrication. Two different polymer overlays, created through a curing process on a conventional engine bearing surface with an approximate thickness of 13 µm, were investigated for their friction and wear resistances under a 30 N load using a pin-on-disc setup. The results indicate that the newly developed polymer overlay (NDP, PAI-based coating) surface has a coefficient of friction (COF) of 0.155 and a wear volume loss of 0.010 cm3. In contrast, the currently used polymer overlay (CPO) in this field shows higher values with a COF of 0.378 and a wear volume loss of 0.024 cm3, which is significantly greater than that of the NDP. It was found that, in addition to accurately selecting the ratios of solid lubricants, polymer resins, and wear-resistant hard particle additives (metal powders, metal oxides, carbides, etc.) within the polymer coating, the effective presence of a transfer film providing low friction on the counter surface also played a crucial role.

Modelling of Static and Dynamic Elastomer Friction in Dry Conditions

Understanding the tribological behavior of elastomers in dry conditions is essential for sealing applications, as dry contact may occur even in lubricated conditions due to local dewetting. In recent decades, Persson and co-authors have developed a comprehensive theory for rubber contact mechanics and dry friction. In this work, their model is implemented and extended, particularly by including static friction based on the bond population model by Juvekar and coworkers. Validation experiments are performed using a tribometer over a wide range of materials, temperatures and speeds. It is shown that the friction model presented in this work can predict the static and dynamic dry friction of various commercial rubber materials with different base polymers (FKM, EPDM and NBR) with an average accuracy of 10%. The model is then used to study the relevance of different elastomer friction contributions under various operating conditions and for different roughness of the counter surface. The present model will help in the development of novel optimized sealing solutions and provide a foundation for future modeling of lubricated elastomer friction.

Antagonistic strategy for enhanced performance polyimide-based triboelectric nanogenerators and wireless self-powered sensors in extremely harsh environments

Triboelectric nanogenerators (TENGs) offer promising green energy solutions for portable microelectronics in the Internet of Everything era. However, their practical applications are limited by low electrical output and stability in harsh environments. This study introduces an innovative antagonistic strategy to enhance TENG performance and stability using thermo-stable polyimide with customizable porous structures (ip-PI). By employing antagonistic solubility, we create ip-PI using chloroform as a solvent for PI and acetone as a solvent for the Poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF-co-HFP) template, whereas they both act as nonsolvents for their respective counterparts. Additionally, microbeads-patterned chitosan (mb-CS) is rationally designed and fabricated as morphologically and electrically antagonistic counter surfaces for ip-PI. The resulting antagonist-inspired TENG (AI-TENG) constructed from ip-PI and mb-CS achieves a remarkable average power density of 4 W·m−2, presenting an outstanding 200-fold increase in power compared to TENG made from unstructured flat surfaces. Furthermore, the ip-PI demonstrates excellent temperature resistance, enabling the TENG to operate at extremely high temperatures up to 250 °C, with promising durability of over 10,000 contact-separation cycles. Applications include self-powered machinery condition monitoring sensors and a wireless communication fire forest pre-warning system, showcasing significant advancements in flexible, high-performance TENGs suitable for industrial use in extreme environments.

Wear of alumina-PTFE against brass and aluminum: Role of interfacial films and tribochemistry

PTFE matrix composites reinforced with α-Al2O3 fillers are considered a gold standard polymeric solid lubricant. α-Al2O3 PTFE exhibits ultra-low wear rates (k ∼10−8 mm3/Nm) when sliding against steel in the presence of water vapor. Mechanochemical interactions involving the breaking of PTFE chains, and subsequent oxidation in the presence of water vapor helps promote growth of interfacial films that are strongly bound to the sliding interface. In the absence of moisture, wear rates of α-Al2O3 PTFE can increase by as much as three orders of magnitude, underscoring its importance to ultra-low wear behavior. A similar increase in wear rates of α-Al2O3 PTFE in humid environments has recently been observed when sliding against brass counter surfaces, though reasons for this increase remain unclear. These findings suggest that mechanisms of ultra-low wear not only rely on ambient humidity but are also strongly dependent on the counter surface chemistry. In the present work, we test the hypothesis that counter surface chemistry drives alumina PTFE wear by systematically investigating the wear of an α-Al2O3 PTFE composite against brass and aluminum substrates within the context of the morphological and mechanochemical evolution of the sliding interface. Wear tests are conducted under reciprocating, dry sliding conditions. Results presented in this work offer insights on mechanochemical mechanisms that drive wear of α-Al2O3 PTFE against brass and aluminum, and provide a framework for developing strategies for controlling wear.

Tribological behaviour of microindented 100Cr6 steel surfaces in dry contact conditions

In the present work, we studied the dry tribological behaviour of a 100Cr6 steel, the spherical surface of which was texturized with microindentation. The purpose of adopting a mechanical indentation technique on a non-planar surface was to simultaneously evaluate the effectiveness of adopting a fast, deformation-based technique for improving the contact tribological properties. Specifically, dimples were created using an automatic microhardness tester equipped with a Vickers indenter, setting a load of 0.5 N. Friction tests were performed at different speeds considering textured surfaces with two different void ratios (VRs). Textured and untextured surfaces were tested using a ball-on-disc tribometer. In addition, the effect of dimple size was evaluated by producing Vickers indented surfaces at a load of 5 N per each indentation, while keeping the VR values unchanged and testing the frictional properties of such surfaces at a fixed speed of 4.18 mm/s. Textured surfaces were deeply investigated to motivate the improvement of tribological properties. Notably, compared to the untextured samples, the microindented samples exhibited a much lower coefficient of friction (COF), with a friction reduction compared to the untextured case ranging from 45 to 65%, depending on the VR values. The adoption of large dimples allowed the reduction of the COF, already at smaller VR value but, in such a case, the presence of bulges at the edge of the dimple worsens the wear resistance of the counter surface. In addition to reducing the contact area and the capability to trap any debris in the dimples, the local measurement of strength allowed to clarify that the friction reduction is also determined by the work hardening effect produced by the microindentation texturing. Considering the significant improvements recorded in terms of COF and the high ability to indent even non-planar surfaces, the proposed approach can be considered very promising and, therefore, industrially applicable (e.g. using a specifically designed multi-indenter tool) to affect the friction behaviour of components, even locally, during both their use and their production.

Investigation of the friction and deformation behaviour of high-speed brakes

Spring-applied brakes are widely used components in industrial drive systems. They provide a braking torque by friction between a mostly organic friction lining and a metallic counter surface. Increasing with decreasing size, they currently achieve speeds of up to 6,000 rpm, which corresponds to a sliding speed in frictional contact of up to 35 m/s. At the same time, there is a trend towards high-speed drives, with speeds of 10,000 rpm and above. So far, little is known about the behaviour of the friction value and torque of conventional spring-applied brakes with low-cost organic friction linings under these operating conditions. For this reason, a test rig was develop - ed that allows testing at sliding speeds of up to 120 m/s with different load inertias. The tests carried out at KAt so far showed that with limited friction work, the conventional spring-applied brake reaches the nominal braking torque at higher sliding speeds. In addition to thermal overload of the friction lining, plastic deformation of the friction bodies can also permanently disrupt the operating behaviour of brakes operated at high sliding speeds. The plastic deformation of the friction discs manifests itself, for example, in a saucer-like shape of the discafs, leading to a reduction in the air gap and causing unwanted changes in the friction conditions. This paper describes the relationship between friction work and friction coefficient in organic linings and the physical mechanism of the deformation process of the friction discs. Based on these possible measures to reduce deformation are explained.

Surface modification of polytetrafluoroethylene (PTFE) fibers through methyl methacrylate (MMA) polymerization for self-lubricating composites

PTFE fibers exhibit strong inertia and possess restricted interfacial compatibility with resin, thereby constraining the application of PTFE self-lubricating composites. To address this issue, PTFE-g-MMA fibers were synthesized by grafting MMA onto the surface of PTFE fibers using high-energy irradiation and chemical grafting techniques, resulting in the enhancement of the tribological properties (the friction coefficient has been reduced by approximately 42.2% and the wear rate has been reduced by about 87.9%) and mechanical properties (the interlaminar shear strength (ILSS) experienced a substantial increase of approximately 45.8%) of the composites. The influence of grafting modification on the formation of PTFE transfer films and the effect of modification time on the tribological properties of composites were investigated systematically. The results indicated that graft modification disrupted the C–F bond of PTFE and promoted the formation of metal-chelated carboxylates, facilitating the formation of PTFE transfer films on the counter surface. This research could provide a general and feasible strategy for large-scale modification of PTFE fibers with exceptional comprehensive properties.

The influence from PTFE on surface and sub-surface damages of glass fiber reinforced PPS

Polymer composites are common materials for tribological components, even at relatively high operating temperatures. One advantage is the possibility to add low friction additives, such as PTFE, to the base material. In this paper the influence of such additives was studied, with focus on surface and sub-surface damages. The polymer composites were PPS with glass fibers (PPS-F), PPS with glass fibers and PTFE (PPS-L) and PEEK with carbon fibers, graphite and PTFE (PEEK-L). A reciprocating ball-on-disc test set-up, with ball bearing steel balls as counter material, was used with 5 N and 15 N normal load. The tests were run for 2,000 and 10,000 cycles in room temperature, 80 °C and 120 °C. PPS-F showed high friction (µ ≈ 0.4–0.5) and severe surface damage of both the polymer and the counter surface. Sub-surface cracks, detachment of fibers from the polymer and a deformed surface layer was revealed, when studied in cross section. The load and temperature had negligible effect on the friction, however a higher temperature resulted in more surface damage of the PPS-F. PPS-L and PEEK-L showed relatively low friction (µ ≈ 0.1) and superficial surface damage. XPS analysis revealed a thin tribofilm of PTFE in the wear track for PPS-L.

Coarse-grained molecular dynamics simulation of the effect of cross-linking on the wear mechanism of polymer brush

Abstract The effects of a cross-linking layer on the wear resistance of polymer brush were investigated by using molecular dynamics-based sliding simulations. We found that a cross-linking layer improved wear resistance. The cross-linking layer suppressed the interpenetration of polymer chains on the counter surface and thus lowered the frictional force and wear. The degrees of interpenetration decreased as the cross-linking layer closed to the tip of the chain. A cross-linking layer in the tip of the polymer chains was thus found to improve wear resistance most effectively.

Reactive Molecular Dynamics Simulation Study on Atomic-Scale Adhesive Wear Mechanisms of Single Crystalline Body-Centered Cubic Iron

The adhesive wear of steel is a crucial issue in many industrial fields because it can lead to serious machine failure. However, the adhesive wear mechanism is still under debate owing to its complexity. Therefore, in this work, we performed reactive molecular dynamics-based sliding simulations of single crystalline body-centered cubic iron and investigated the fundamental atomic-scale adhesive wear mechanism for improving the wear resistance of steel. The effects of surface orientation, sliding direction, and humid atmosphere on the adhesive wear property were analyzed. In the sliding simulation, we observed two adhesive wear types. One is the wear accompanying surface deformation, in which the surface asperities gradually deform by slip and adhere severely. The other is the wear accompanying surface fracture with crack generation. The former can lead to seizures, whereas the latter can lead to wear debris formation. We propose that the rubbing surface orientation and sliding direction alter the atomic-scale adhesive wear type. Wear with surface deformation occurred when the deformation by slip was favorable, whereas wear with surface fracture occurred when slip was not favorable. Understanding the adhesive wear mechanism of iron in humid atmospheres is also important in many industrial fields. When water molecules were present at the sliding interface, both types of adhesive wear were suppressed. At the sliding interface, Fe–OH and Fe–O–Fe groups were formed on the scars through the tribochemical reaction with water. These groups passivated the nascent Fe surfaces and suppressed adhesion to the counter surface, thereby reducing adhesive wear. Therefore, we conclude that the surface orientation and sliding direction determine the atomic-scale adhesive wear type, whereas a humid atmosphere affects the wear amount at the atomic scale.

Friction and wear performance of polyether ether ketone (PEEK) polymers in three lubrication regimes

This experimental study investigates the friction and wear of three coatings commonly used in industrial applications, particularly in hydrodynamic bearings. The three materials under investigation were Babbitt, polyether ether ketone (PEEK) reinforced with 15% carbon fibers, and PEEK reinforced with 20% carbon fibers. The first polymer material was extruded, while the other was produced by fused deposition modelling (FDM). The materials were subjected to sliding tests in a pin-on-disc configuration, with a steel ball serving as the counter surface. The tests were conducted at room temperature, with a load of 10 N and under three different lubrication conditions: dry, grease, and oil. The linear speed was set at 0.3 m/s for the dry and semi-solid lubrication tests, while for the oil tests, the speed was set at 0.25 m/s. The greases used had consistency grades of NGLI 000 and NGLI 2. An ISO VG 68 circulation oil was used for the oil lubrication tests. Additionally, thermodynamic analyses were performed under the most severe conditions (i.e., dry) to investigate the steel-Babbitt and steel-PEEK contact.

Sliding friction of a pillar array interface: part II, contact mechanics of single pillar pairs.

Insects and small animals often utilize structured surfaces to create friction during their movements. These surfaces typically consist of pillar-like fibrils that interact with a counter surface. Understanding the mechanical interaction between such surfaces is crucial for designing structured surfaces for engineering applications. In the first part of our study, we examined friction between poly(dimethylsiloxane) (PDMS) samples with surfaces patterned with pillar-arrays. We observed that sliding between these surfaces occurs through the interfacial glide of dislocation structures. The frictional force that resists this dislocation glide is a result of periodic single pillar-pillar contact and sliding. Hence, comprehending the intricate interaction between individual pillar contacts is a fundamental prerequisite for accurately modeling the friction behavior of the pillar array. In this second part of the study, we thoroughly investigated the contact interaction between two pillars located on opposite sides of an interface, with different lateral and vertical offsets. We conducted experiments using PDMS pillars to measure both the reaction shear and normal forces. Contact interaction between pillars was then studied using finite element (FE) simulations with the Coulomb friction model, which yielded results that aligned well with the experimental data. Our result offers a fundamental solution for comprehending how fibrillar surfaces contact and interact during sliding, which has broad applications in both natural and artificial surfaces.

A compendium of all-in-one solar-driven water splitting using ZnIn2S4-based photocatalysts: guiding the path from the past to the limitless future.

Photocatalytic water splitting represents a leading approach to harness the abundant solar energy, producing hydrogen as a clean and sustainable energy carrier. Zinc indium sulfide (ZIS) emerges as one of the most captivating candidates attributed to its unique physicochemical and photophysical properties, attracting much interest and holding significant promise in this domain. To develop a highly efficient ZIS-based photocatalytic system for green energy production, it is paramount to comprehensively understand the strengths and limitations of ZIS, particularly within the framework of solar-driven water splitting. This review elucidates the three sequential steps that govern the overall efficiency of ZIS with a sharp focus on the mechanisms and inherent drawbacks associated with each phase, including commonly overlooked aspects such as the jeopardising photocorrosion issue, the neglected oxidative counter surface reaction kinetics in overall water splitting, the sluggish photocarrier dynamics and the undesired side redox reactions. Multifarious material design strategies are discussed to specifically mitigate the formidable limitations and bottleneck issues. This review concludes with the current state of ZIS-based photocatalytic water splitting systems, followed by personal perspectives aimed at elevating the field to practical consideration for future endeavours towards sustainable hydrogen production through solar-driven water splitting.

The Tribological Behavior of Cast Iron by Laser Surface Texturing under Oil-Lubricated Initial Line Contact for Rotary Compressor

The tribological behaviors of cast iron by laser surface texturing were experimentally compared with the behavior of untextured by unidirectional rotary sliding friction and wear tests under oil-lubricated initial line contact. The friction coefficient and temperature rise were analyzed with the increasing load applied by block-on-ring tests. In addition, the wear loss and wear mechanism were also investigated through the surface topographies analysis. The results showed that the tribological improvement strongly depended on the contact form. For the oil-lubricated initial line contact in this work, the textured surface showed a better frictional advantage with a lower friction coefficient and lower temperature rise. The hydrodynamic effect enhanced the load-carrying capacity of the oil film and increased the film thickness. The friction coefficients were 11~64% lower than those on the untextured one. Meanwhile, the textured surface deteriorated the wear behavior due to the coupling effect between the micro-cutting effect of the texture edges and the material deformations of the counter surface. The material loss induced by abrasive wear and fatigue wear was the dominant wear mechanism. Namely, the laser surface texturing improved the friction properties but reduced the wear resistance.

Tribological Performance of Steel/W-DLC and W-DLC/W-DLC in a Solid–Liquid Lubrication System Additivated with Ultrathin MoS2 Nanosheets

In this paper, MoS2 nanosheets with an ultrathin structure were fabricated using a solvothermal method and further added into PAO oil, which was further combined with W-DLC coating to constitute a solid–liquid lubricating state. The influences of MoS2 concentration, applied load and counter surfaces on the lubricating of the solid–liquid hybrid lubricating system were explored through a ball-on-disk tribometer. The friction results indicated that the steel/W-DLC and W-DLC/W-DLC tribopairs lubricated with ultrathin MoS2 possessed better friction reduction and wear resistance behaviors in comparison to pure PAO oil. However, compared to the steel/steel couple case, the prepared MoS2 nanosheets exhibited a more efficient lubricating effect for the W-DLC/W-DLC couple. The beneficial boundary lubricating impact of MoS2 nanosheets on self-mated W-DLC coated rubbing surfaces could be attributed to the tribochemical reaction between MoS2 and doping W element in DLC, resulting in a formation of a thin tribofilm at both counterparts. Meanwhile, the extent of graphitization of W-DLC film induced by friction was alleviated because of the lubrication and protection from the formation of MoS2-based tribofilm at both counterparts.

Squeeze infiltration processing of lightweight smart aluminum graphite functionally graded composite for enhanced wear resistance

Aluminum - Graphite functionally graded metal matrix composites (A356-Gr FGMMC) with 20‐60 volume percentage (vol%) of natural graphite (Gr) as reinforcement are developed by liquid metal squeeze infiltration technique. The density of A356-Gr FGMMC with 60 % Gr is reduced by 27 % (1.968 g/cm3) in particle rich region from the value of the base A356 alloy (2.68 g/cm3) making the FGMMC lighter. In comparison to monolithic A356 alloy, the coefficient of thermal expansion (CTE) of composites decreases with an increase in the volume fraction of Gr reinforcement. The CTE value is significantly reduced from 22.24 × 10−6/°C for A356 alloy to 9.62 × 10−6/°C for the composite with 60 % Gr. With the addition of Gr from 20 % to 60 %, the microhardness is found to be decreased from 74 HV to 46 HV and the compressive strength decreased from 364 MPa for the unreinforced matrix to 42 MPa for A356-Gr FGMMC with 60 % of Gr addition. Wear studies carried out on A356-Gr FGMMC using pin-on-disc tribometer shows excellent wear resistance with the addition of Gr particles compared to matrix alloy. The wear rate reduces with increasing Gr vol%, reaching a minimum at 60 % Gr. The scanning electron microscopy (SEM) analysis of worn surfaces indicate the formation of self-lubricating tribolayer which limits the interaction between matrix metal and the counter surface leading to the development of a smart composite with functionally graded properties in the particle rich region.

Tribological performance of PTFE-ATSP and PTFE-Ekonol polymer blends aimed for oil-less engineering applications

This study examines the tribological performance of an advanced high-performance polymer (HPP), namely aromatic thermosetting copolyester (ATSP), and poly-hydroxybenzoic acid polymer or Ekonol® as additives for polytetrafluoroethylene (PTFE), under unlubricated conditions from room temperature to 300 °C. Compared to PTFE-Ekonol composites, PTFE-ATSP blends showed 50% reduction in the wear rate at all tested temperatures and higher wear resistance at different sliding speeds, partially attributed to its viscoelastic stability or higher mechanical strength. Also, a fluoride-rich lubricating transfer film was formed on the metallic counter surface when tested against PTFE-ATSP, and this film is temperature-dependent. PTFE-ATSP blends are an attractive solution for oil-less applications in the temperature range of 25–300 °C.

Radial shaft seal with different relative velocities and on a 3D printed counter surface

PurposeThe purpose of this study is asking for a methodologically representable relation between different relative velocity approaches, counter surfaces and the tribological behavior of the radial shaft seal (RSS).Design/methodology/approachThe tribological behavior between the seal and the counterpart is examined experimentally to submit significant measured values. The correlations among seal elements, relative velocity approaches and counter surfaces with more aspects are searched.FindingsA basis for future research regarding optimization options for service life extension of the RSS under different operation environments has been set. New insights for the performance of 3D-printed counter surface are gained as well as the application possibility of that is searched.Originality/valueThe applied measuring procedure in investigation part especially the usage of different approaches in relative velocity approaches is designed with originality. In particularly, the usage of a 3D-printed counter surface comes for the first time in a scientific work.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-11-2022-0325/