Formation Of Lubricating Film Research Articles

Investigation of tribological performance of the ultra-dispersive TBC-CNTs as additives for aqueous lubrication

Carbon nanotubes (CNTs), as water-based additives, are potential candidates for reducing friction and wear whereas the weak dispersion stability impedes their application in aqueous lubrication. Therefore, CNTs were functionally modified by 4-tert-butylcatechol (TBC) nucleophilic for synthesizing the ultra-dispersive TBC-CNTs. The particle sizes and dispersibility of TBC-CNTs in water were investigated. It was found that particle sizes of the most of CNTs were reduced after modification and 0.035 wt% TBC-CNTs remained uniformly dispersed in water for 2 months. The lubrication behavior of TBC-CNTs as water-based additives for ceramic/steel tribo-pairs was investigated by using a ball-on-disc apparatus. Notably, the optimum concentration of TBC-CNTs was determined 0.2 wt% that contributed to 30.6 % of friction reduction and 28.3 % of wear resistance, respectively, at 0.6 m/s and 8 N. The tiny structure of TBC-CNTs contributed to their entrance into the contact interface and playing lubricating roles. Furtherly, the increase of water film thickness within contacts and formation of lubrication film on rubbing surfaces caused by TBC-CNTs addition resulted in the friction and wear reduction.

EHD simulation study on the influence of measured ICE compression piston ring profiles on the lubrication film formation

In this simulation-based research, the authors investigate the influence of the contacting profile and its tilting orientation of original compression piston rings on their hydrodynamic properties in internal combustion engines (ICEs). They employ a systematic approach, detailing the computational framework and simulation parameters. Three different original piston rings belonged to the same engine are used for the simulation and corresponding experimental validation in this publication. Resultsand discussions highlight the directional dependence of hydrodynamic conditions, with distinct differences for individual rings. Original smoothed profiles are compared with substitute geometries like quadratic parabola and circular arc fits. The research contributes insights into the complex dynamics of compression rings in ICEs, providing a foundation for optimizing ring profiles for enhanced hydrodynamic properties.

Influence of CePO4 on high temperature anti-friction and anti-wear behaviors of nickel-based h-BN composite coatings

Solid lubricating coatings which offer and maintain anti-friction and anti-wear are urging to develop in the advanced technology applications over a wide range of temperatures. The h-BN composite coatings on the Inconel X750 superalloy is prepared by spark plasma sintering (SPS) technology to obtain low friction and wear over a broad temperature ranging from room temperature (RT) to 800 °C using a high temperature rotary tribometer. The influence of the contents of h-BN and CePO4 powders of the tribological properties of the composite coatings was studied systemically under different temperatures. The experimental results show that the composite coatings with 20 wt% h-BN show excellent high temperature anti-friction behaviors. Coefficient of friction (CoF) of the composite coatings with 20 wt% h-BN with CePO4 powder is lowest about 0.12 among the composite coatings at 800 °C. The CePO4 powders are helpful to improve the sintering behaviors and reduce the wear rate of the composite coatings at elevated temperature. The synergistic lubrication mechanism of h-BN and CePO4 of the composite coatings are investigated systematically. The high temperature anti-friction and anti-wear mechanism of the composite coatings is due to the formation of a layered gradient lubrication film on the worn surface.

The effect of MoS2 concentration on the thickness and tribology performance of electro-codeposited Ni–Cr–MoS2 coatings

A Ni–Cr–MoS2 coating with trivalent Cr was prepared on the surface of the cylinder liner by the composite co-deposition method to modify its tribology performance. The effects of MoS2 concentration on the properties of the coatings and tribological properties of cylinder liners were studied by surface detection methods and reciprocating wear tests. The results show that Ni–Cr–MoS2 coating has a smaller grain size, higher micro-hardness, and greater coating thickness, compared with Ni–Cr coating. Doping by MoS2 effectively reduces the friction coefficient of Ni–Cr coating from 0.142 to 0.107, the wear amount of coating decreases from 7.9 mg to 7.1 mg, and the scuffing time increases from 19 min to 56 min. It is found that the doping of MoS2 provided more nucleation sites and promoted the deposition of ions, which resulted in the refined grain and thicker coating. The formation of solid lubrication film by MoS2 during the wear process and more coating thickness are mainly responsible for the modification of the tribology performance of cylinder liners. This research provides a practical approach to prolong the service life of friction pairs.

Droplet migration through deformable stenosed microchannel: Dynamics and blockage

Understanding droplet migration in stenosed microchannels is crucial for various applications. This study explores how droplet properties (viscosity, surface tension, density, and diameter) and channel characteristics (stenosis degree and wall elasticity) affect droplet movement and blockage in deformable stenosed microchannels. Higher viscosities lead to lubrication film formation between droplet and wall, reducing viscous resistance, while increased surface tension enhances wall adherence, amplifying Laplace pressure. Droplet entry is primarily influenced by viscosity, while passage is governed by surface tension and curvature effects at the droplet–wall interface. Surface tension dominates pressure generation in the channel and within the droplet, influencing wall deformation and hydrodynamic resistance. The study examines the relationship among droplet viscosity, density, surface tension, channel wall elasticity, and the maximum capillary number (Camax) on the lubrication film thickness between the droplet and the channel wall. A lubrication film exists for Camax≥0.095, reducing blockage chances. A critical range of the modified Ohnesorge number Oh*×1000≤132 and the capillary number (Camax<0.095) indicates higher chances of droplet blockage. The blockage prediction method based on the modified Ohnesorge exhibits a sensitivity of 100%, specificity of 92.6%, and accuracy of 95.9%. Additionally, the study explores the impact of channel wall elasticity on droplet entry, transit, and hydrodynamic resistance. Higher wall elasticity facilitates faster entry but introduces curvature during passage, increasing frictional resistance and blockage likelihood as the wall softens.

Ultra-low friction system using special wetting interfaces: Bridging across various wetting regimes

Friction was the main way of energy loss in society, and reducing friction has become a focal point in current research. Inspired by special wetting phenomena, an asymmetric multiphase composite (AMPC) friction system was constructed. Tribological behavior of the friction system was evaluated using hydrogel on anodized aluminum as friction pair and superhydrophobic alumina with micro/nano-composite as substrate. Ultra-low friction coefficients (∼10−3) were measured under both Cassie and Wenzel regimes. Especially in Wenzel state, increased contact stress or extended shear rate promoted the formation of transfer lubricant film, thus enabling the ultra-low friction coefficient. Moreover, the system showed mechanical stability during prolonged water lubrication. This novel lubrication approach may provide valuable scientific solutions for specific tribology applications.

Impact of grease physical properties on the friction torque and service life of wheel bearings

Wheel bearings play a crucial role in ensuring the smooth and reliable rotation of wheels in automotive applications. Grease is commonly used as a lubricant in wheel bearings. The physical properties of grease, such as viscosity, base oil type, and thickener composition, significantly influence the overall performance and longevity of wheel bearings. This study investigates the impact of grease's physical properties on wheel bearing friction torque and service life. To evaluate the effects of different grease formulations, a series of experiments were conducted using a four-ball tester, rheometer, and a custom-built test rig to measure bearing frictional torque and service life. Multiple greases with varying viscosity grades, base oil types (mineral oil, synthetic oil), and thickener compositions (lithium, diurea, and polyurea) were tested under controlled operating conditions. Friction torque measurements were obtained using a high-accuracy torque sensor, while service life was determined by monitoring the bearing life in actual endurance testing. The results indicated that grease physical properties directly affected wheel bearing friction torque and service life. Low to Medium-viscosity greases generally exhibited 35–40% lower friction torque due to enhanced lubrication film formation and reduced metal-to-metal contact however, excessively high viscosity resulted in 50–60% higher frictional torque and thereby increased energy consumption. Different base oil types showed varying friction reduction and service life level, with mineral oil in some cases showed lower frictional torque around 30–40% particularly at high temperature but with significant reduction in the service life. Furthermore, the thickener composition significantly influenced grease performance. Based on these findings, selecting the appropriate grease with optimal physical properties is crucial for minimizing friction torque and extending the service life of wheel bearings.

Investigation of Graphene Platelet-Based Dry Lubricating Film Formation in Tribological Contacts

Dry lubricants used in highly loaded rolling bearings are in the focus of current research. In previous studies, graphene platelets applied as dry lubricants on the surfaces of angular contact ball bearings demonstrated superior properties. These specific bearings, experiencing both rolling and spinning motion, create more severe conditions for dry lubricants. To gain deeper insights into the lubrication effects, micro-tribological studies were carried out on the respective film formation and running behavior effects. In the tests, a fixed steel ball slid against an oscillating counterpart under a defined load. During the measurements, the applied load and tangential forces on the ball were recorded to calculate the friction. Comparative investigations included nano-graphite particles and fullerene as dry lubricants, in addition to graphene platelets of various staple thicknesses. To increase the adhesion of the films to the surfaces, a pre-rolling process was implemented. Afterwards, the friction on the compressed films was measured. The results indicate that the pre-rolling process effectively reduces the friction of the system. After testing, the surfaces underwent analysis using laser scanning microscopy to assess the formed films, wear, and material transfer. It has been demonstrated that the pre-rolling process leads to the formation of a very thin compacted film with surface protective properties. With the ball as a counterpart, the graphene platelets generate a transfer film on the contacting surface.

Effects of Oil and Solid Body Temperatures on Elastohydrodynamic Lubrication Film Formation

The present study focuses on investigating the influence of oil and solid body temperatures on elastohydrodynamic lubrication (EHL) film formation. Experimental and numerical simulation methods are employed to examine three heating methods: oil and ball heating, disc heating, and entire system heating. A preliminary comparison between the measured results and numerical simulations confirms the impact of heating methods on film formation while validating the availability of the numerical models. Further numerical analysis reveals that in the case of oil and ball heating, the temperature gradient induced by differences in solid body temperatures plays a more significant role in film formation compared to the conventional thermal-viscosity wedge effect caused by EHL film shear. This effect is further amplified at large sliding–rolling ratios and in steel–steel contacts. The overall film formation is primarily governed by the oil inlet temperature, whereas local film formation characterized by a dimple shape is influenced by both thermal gradient effects and thermal-viscosity wedge effects. This study provides valuable insights for selecting appropriate heating methods in experiments as well as understanding how temperature differences affect film formation in practical engineering.

Tribological Behavior and Mechanism of Surface-Modified Mullite as Polyurea Grease Additive

Abstract The excellent tribological performance of nanoparticles as additives in lubricating greases has attracted widespread attention. In this study, a silane coupling agent (KH550) was used to chemically modify nanoscale mullite (composed of Al2O3 and SiO2), and the modified nano-KH-mullite was dispersed as an additive in polyurea grease at different ratios (0.01, 0.05, 0.07, 0.1, and 0.3 wt%). The friction and wear performance of the compound polyurea greases were evaluated using a four-ball friction tester. Professional instruments will be utilized to analyze the micro-morphology, 3D profile, elemental content, and valence state of the worn surface, aiming to investigate the lubrication and antiwear mechanism of the nano-KH-mullite additive. The results indicate that nano-mullite effectively improves the antiwear and antifriction performance of the polyurea grease. When the additional content is 0.05 wt%, the friction coefficient (COF) and the wear scar diameter (WSD) are reduced by approximately 19.97% and 11.1%, respectively, and the roughness of the worn surface is also reduced. The excellent tribological performance of the composite grease is attributed not only to the good dispersibility of KH-mullite but also to its ability to promote the formation of a composite lubrication film on the friction pair surface. The component KH-Al2O3 in the KH-mullite can fill and repair scratches and grooves on the worn surface, while the other component KH-SiO2 can bear the load and convert the friction mode to rolling friction.

Diagnosis and root cause analysis of bearing failure using vibration analysis techniques

This paper is presented to diagnose and root cause analysis of the bearing failure. For this purpose, a vibration investigation was carried out on a motor with a 2300 kW power, 1489 rpm speed. Bearing failure was diagnosed by trending and analyzing vibration parameters. By investigating the bearing damage morphologies, a false brinelling pattern was observed. To find the failure cause, the machine was evaluated for two aspects; vibrations and lubrication. The resonance in the fan and the lack of full lubrication film formation were considered root causes of failure. To mitigate resonance, changing the operating speed was considered as a corrective action. By increasing the operating speed (1491 to 1530), the vibration amplitude decreased by nearly 21%. Also, the thickness of the lubricating film was improved by installing an airflow hose. Using this method, the time between failures increased from 3 to 11 months.

Deterministic Simulation of Surface Textures for the Piston Ring/Cylinder Liner System in a Free Piston Linear Engine

The use of synthesis gas (SYNGAS) from waste gasification has been pointed out as a key strategy to help the energy transition. However, SYNGAS’ low calorific power is considered a difficult obstacle to its technological use in internal combustion engines. To overcome this, a novel free-piston linear motor has been proposed to pave the way for the use of SYNGAS in the mobility sector. Surface texturing has vast potential to reduce friction losses in this system. This study utilizes a deterministic numerical model to investigate the mixed lubrication performance of a textured piston ring/cylinder liner conjunction in a free piston engine. The model considers the simultaneous solution of the lubrication and asperity contact problems at the roughness scale, including texturing features on the cylinder surface. The numerical model employs the Reynolds equation with mass-conserving cavitation to calculate the inter-asperity fluid pressure. The rough contact model utilizes the Hertz theory for elastic contact to calculate the contact pressure at each asperity between the piston liner surface and the admitted smooth and rigid ring surface. Surface texturing demonstrated remarkable effectiveness, particularly in the hydrodynamic lubrication regime, with a maximum friction reduction of 38.5% observed for an area coverage of 50%. This was accompanied by a notable shift in the transition from the boundary to the mixed lubrication regime. The textured surfaces exhibited consistent efficiency in reducing fluid pressure and shear stress as the coverage of the textured areas increased. The incorporation of dimples on these surfaces played a crucial role by augmenting the lubricant storage capacity while concurrently reducing the real shear and contact areas. This study offers valuable insights into the nuanced friction-reducing mechanisms of surface textures, illuminating their influence on the coefficient of friction and the formation of lubricant films across various lubrication regimes.

Microstructure, mechanical and tribological properties of APC/Al laminated composites prepared by hydrothermal carbon adsorption on plates

Amorphous carbon (APC)/Al laminated composites were prepared by hydrothermal carbon adsorption on plates (HTCAP) and vacuum hot-press sintering process. The effect of the glucose solution concentration on the microstructure, mechanical properties and tribological properties was investigated. The results indicate that APC is uniformly distributed between layers and has good interfacial bonding with the matrix through the diffusion of Al. As the glucose solution concentration increases, the interlayer hardness, ultimate tensile strength and elongation first increase and then decrease, while the wear rate shows the opposite trend and the coefficient of friction (COF) gradually decreases. A maximum elongation of 16.4% and a minimum wear rate of 0.344×10−5 mm3/(N·m) are achieved at a glucose solution concentration of 0.3 mol/L. Adhesive wear is the dominant wear mechanism of APC/Al laminated composites. The improvement in wear resistance is attributed to the formation of uniform APC lubrication film on the wear surface.

Enhancement of the mechanical and tribological properties of carboxylated acrylonitrile butadiene rubber filled with cryptocrystalline graphite by different preparation methods

AbstractAs a cost‐effective and environmentally friendly natural mineral, cryptocrystalline graphite (CG) is applied in rubber materials and its performance has been evaluated. In this work, the filler dispersion and mechanical and tribological properties of carboxylated acrylonitrile butadiene rubber (XNBR)/CG composites by different preparation methods were studied. XNBR/CG composites prepared by latex blending (XNBR/CG‐L) exhibited better mechanical and tribological performance, higher toughness, and lower heat build‐up than those prepared by mechanical blending (XNBR/CG‐M). These differences were ascribed to the filler dispersion degree, filler amount and dispersed size, and also filler–rubber interfacial interaction. Adding CG was conducive to improving the stability of the friction coefficient and reduced the wear rate via the formation of graphite lubricant and transfer films. The tribological performance of XNBR/CG‐L was superior to that of XNBR/CG‐M because of the improved tensile strength, tear resistance, and toughness as well as lower temperature rise. Scanning electron microscopy (SEM) and optical microscope observation showed a smoother worn surface, less and smaller wear debris of XNBR/CG‐L, and a more uniform transfer film on the steel counterpart surface. The relevant results provided new insight into the performance and structural design of CG/rubber composites.

Cutting performance and cutting fluid infiltration characteristics into tool-chip interface during MQL milling

The insufficient infiltration of cutting fluid at the tool-chip contact interface during machining poses a substantial challenge to achieving clean and efficient cutting processes. Key to enhancing the infiltration efficiency of cutting fluids lies in understanding their penetrative characteristics within the tool-chip cutting region. Thus, analyzing the milling performance under varying lubrication environments and cutting parameters forms a fundamental prerequisite to this research. In this study, we experimentally investigated the influences of cutting parameters on cutting force and cutting temperature in dry and minimum quantity lubricant (MQL) milling. In addition, we presented the friction state at the tool-chip interface, incorporating the friction coefficient into our analysis. Moreover, we explored the infiltration characteristics of oil mist fluid within the tool-chip contact region via fluid simulations. The tool wear mechanisms under various lubrication conditions were also elucidated. Subsequently, we established three-stage infiltration models to ascertain the conditions conducive to the formation of stable lubricating films and revealed the internal mechanisms dictating MQL penetration. The results disclose that the cutting force, cutting temperature, and friction coefficient of MQL milling decrease by 10–25%, 9%, and 16% respectively at a cutting speed of vc = 100 m/min, feed rate of fz = 0.4 mm/rev, and axial cutting depth of ap = 0.3 mm. However, as cutting parameters increase, the MQL's ameliorative effect on cutting performance diminishes. The underlying cause for this is the expansion of the tool-chip contact length and the increased chip curling radius, which significantly obstruct the injection of MQL oil mist droplets, resulting in a weakened infiltration effect. In conjunction with the conditions necessary for lubricating film formation, it is evident that an increase in cutting parameters is detrimental to improving the infiltration capacity of the cutting fluid into the capillary.

Effect of Oil Dispersion on Lubricating Film Thickness Generation under Oil Droplet Supply Conditions

Oil–air lubrication has proven to be very effective for high-speed bearings because the oil supply in the form of droplets can be precisely controlled. This work uses optical interferometry to study the mechanism of lubricating film formation in rolling point contact with oil droplet lubrication. The effect of a double oil drop pair, where two oil droplets are positioned in mirror images about the central axis of the lubricated track, is examined. The process by which pairs of oil droplets approach and lubricate a bearing contact is analysed. This study also covers the effect of multiple oil droplets supplied in a tailored or a random dispersion pattern. Additionally, the effects of oil viscosity, entrainment velocity, and droplet distribution on starvation are also investigated.

Self‐lubricating epoxy composite coating with linseed oil microcapsule self‐healing functionality

AbstractCured epoxy resins have poor abrasion resistance, which shortens the service life of the material. This work aims to improve the tribological properties of epoxy resins by coupling self‐lubrication and auto‐healing. In this study, linseed oil microcapsules with an average particle size of 38.57 μm and good thermal stability were successfully prepared by in situ polymerization. The effects of microcapsule content on the tribological, mechanical, and self‐healing properties of the composite coatings were studied. It was demonstrated that the composite coating has outstanding self‐lubricating properties. The coefficient of friction reduced from 0.634 (pure epoxy resin) to 0.0459 (epoxy resin with 10 wt.% linseed oil microcapsules). Wear rate reduced from 7.16 × 10−4 mm3/(N m) to 1.74 × 10−5 mm3/(N m). The self‐lubricating mechanism of the coating was investigated by SEM and EDS, which indicated that the formation of uniform and continuous lubricating film on the surface of the friction pairs was the key to improving the wear resistance of the material. In addition, the linseed oil released after the microcapsules rupture can repair the abrasion marks by reacting with oxygen during the friction process. The dual‐functional effect of linseed oil microcapsules prolongs the life of epoxy resin coating and expands its application range.

Contribution of viscous shear to friction in cold rolling of low-carbon steel

This work shows that for temperatures, pressures and shear rates that are common in cold rolling of low-carbon steel, viscous shear stress significantly contributes to the total friction force. Experiments were carried out to validate the theory on lubricant film formation and elasto-hydrodynamic lubrication, both with laboratory scale tribometers and a semi-industrial pilot mill facility. These experiments showed that at high shear rates, that are common in cold rolling, the lubricant does not behave as a Newtonian fluid anymore; moreover the viscosity at high pressure cannot accurately be described by a simple exponential law. With the correct relations implemented in a rolling model, both rolling force and forward slip are predicted with good accuracy for hydrodynamically lubricated cold rolling experiments.

Deterministic surface roughness effects on elastic material contact with shear thinning fluid media

Abstract The formation of lubrication films is described using the hydrodynamic lubrication theory, which is based on the Reynolds equation that includes shear thinning behaviors of lubricant. Contacting surfaces are considered to undergo elastic deformation owing to concentrated contact pressures that exceed 1.0 GPa in most engineering applications. Under the contact condition of a high load on a relatively small contact area, elastic deformation of contacting bodies directly influences the formation of the lubricated film. Elastohydrodynamic lubrication (EHL) analysis is applied to correctly analyze the lubricated contact. Under an EHL contact, the scale of the lubrication film thickness is frequently less than that of the surface roughness that results from either the manufacturing or running-in processes. In this work, surface roughness is considered in detail, and two-dimensional surface roughness is measured as that characterizing general engineering surface roughness. The deterministic method regarding the surface roughness is considered for computing EHL film formation under several contact conditions such as load, contact velocity, and elasticity of contacting materials.

Effect of Friction Parameters on Tribological Properties of Erucamide as Grease Additive on GCr15 Steel

Abstract The present study investigates the effect of friction parameters on tribological properties of erucamide as an additive in grease on GCr15 steel, as well as the sensitivity of erucamide to these parameters. An orthogonal test design is utilized to sample the friction parameters, followed by the construction of a Kriging model to articulate the relationship between these parameters and the designated objectives (average friction coefficient and wear volume). The Non-dominated Sorting Genetic Algorithm II (NSGA-II) is used to optimize the design objectives and verify the accuracy of the model. The Monte Carlo method is used to analyze the sensitivity of erucamide to the friction parameters. The results showed that erucamide exhibits excellent tribological properties at 80 N/20 Hz/25 °C and 20 N/20 Hz/25 °C. The sensitivity of erucamide to friction parameters from high to low is temperature, load, and speed. This can be ascribed to erucamide's unique structure, encompassing a globular aggregation head and a hydrophobic tail extending outward. The anti-friction effects and lubrication properties of erucamide are driven by its rheological properties and intermolecular interactions. At elevated temperatures, erucamide's fluidity escalates, favoring the lubricating film formation; however, excessive fluidity may impede its adherence to requisite locations, thereby resulting in compromised tribological properties of erucamide at high temperatures.