Boundary Lubrication Mechanisms - A Systems Approach
Transcript of Boundary Lubrication Mechanisms - A Systems Approach
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Boundary Lubrication Mechanisms –A Systems Approach
Oyelayo AjayiTribology Section
OFCVS Heavy Vehicle Systems Program Review
April 19, 2006
Team Members Jeffery Hershberger
Cinta Lorenzo-MartinOsman EryilmazAli Erdemir George FenskeJules Routbort
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Identified 21st Century Truck Program Technical Need
From 21 CTP technology road map: “Friction, wear, and lubrication limit engine efficiency. Higher in-cylinder temperatures necessary for higher efficiency require significant advances in tribology”
Stated need: “Develop a better understanding of frictional effects, and develop materials and lubricants with enhanced tribological properties to address the multiple surface interactions that occur in heavy vehicle systems. – An important means to reduce parasitic loss
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Tribology dependent systems in Heavy Vehicles
Fuel Injectors
Valve-Train Components
Rings/Liners
Turbochargers
Liquid Lubricants
Bearings & Gears
Axles Transmission- Eaton
Diesel engine- Ricardo- Caterpillar
• Friction reduction by effective lubrication of pertinent components can translate to significant improvement in system efficiency.
• Analysis shows possible efficiency gain• Engine - > 4%• Transmission - 2 – 5%• Axle - 2%
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Background - Lubrication Regimes
Lubricant fluid film knowledge relatively matured through elastohydrodynamics (EHD) theory and experiments
Boundary lubrication is complex:–Poor understanding of chemical films and near-surface material behavior
Three main lubrication regime depending on the ratio of lubricant film thickness to the composite surface roughness – so called λ ratio
Biggest payoff in terms of friction reduction is in the boundary regime.
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Challenges of Boundary LubricationBoundary lubrication regime involves the three structural elements simultaneously and changes continuously with time.
– Requires system engineering approach of integration of the behavior of the three elements.– Current approach is Edisonian trial and error.
Unable to characterize formation and properties of boundary films and changes in material surface in real time.- Post-test analysis after surface cleaning.- Parametric studies for wear and scuffing
Opportunity:New tools and technology to facilitate in-situ analysis of boundary film formation and properties measurement, as well as dynamic changes in material surface.-APS at Argonne-Scanning probe microscopy (AFM, STM ….)- Nano indentation
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Project Goals and Technical ApproachDevelop better understanding of boundary lubrication mechanisms and the failures therein using a system engineering approach – Facilitate development of reliable low-friction components and systems.
• Characterize dynamic changes in the near surface material duringfailure (catastrophic scuffing as a model) – materials development.
• Determine basic mechanism of chemical surface film lubrication (formation and loss rates, failure mechanisms) – lubricant development.
• Establish and validate frictional performance and tribological failure prediction methodology – integrate into analysis tools.
• Integrate surface modification technologies (e.g. coatings) with lubrication technologies for optimal system performance.
• Transfer knowledge gained and technology developed to industry.
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Project Plan and Structure
Near-surface-material dynamicchanges: - scuffing
Boundary film formation and loss rate: - APS, other tools
Basic mechanism of failure Properties of boundary films
Role of surface modification:- coatings
Models for film formation and behavior
Integrate both elements with EHD to formulate failure/performance prediction methodology
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Summary of Technical AccomplishmentsDeveloped a model for scuffing failure in steel material –initiation and propagation stages.– initiation based on adiabatic shear plastic instability which occurs when
rate of thermal softening exceeds rate of work hardening.– Scuffing propagation is determined by contact heat management–
balancing heat generation and dissipation.
Characterized tribochemical films formed by several model lubricant additives with a various x-ray analytical techniques at APS.– Showed differences between films generated by two different method
from the same additive.– Designed and constructed x-ray accessible tribo tester
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Before scuffing
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•Ring-on-block configuration
•Material: Hardened 4340 steel
•Lubricant: Synthetic basestock
•Speed: 1000 rpm
•Protocol: Step load increase
Scuffing Test
Definition: Sudden catastrophic failure of lubricated sliding surfaces, usually accompanied by rapid rise in friction, temperature, and noise/vibration
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Proposed Scuffing Initiation Mechanism
Based on microstructural changes during scuffing, adiabatic plastic instability mechanism is proposed for initiation of scuffing failure.-- crossover point between work hardening and thermal softening
Some criteria for shear plastic instability e.g.
Critical shear strain:γ = shear strainn = work hardening indexρ = densityCv = specific heat capacityτ = shear strengthT = temperature
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Propagation of Scuffing damage
Sometimes scuffing will initiate without propagating-Micro-scuffing-Scuff quenching
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Scuffing Propagates – heat generation rate exceeds heat dissipation rate
δ
δρλ
ργβτ
δ
XT
XT
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CCdtd
∂∂
⎟⎟⎠
⎞⎜⎜⎝
⎛∂∂−
∂∂−
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2&
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δScuff area
Simplified governing equation for scuffing propagation - 1D
Velocity of shear instability front
β = fraction of plastic work converted to heat (0.9)
τ = Shear stressλ = Thermal conductivityγ = Strain rate
Average plastic work rate
Rate of heat conduction across the boundary
Temperature gradient at boundary
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Further Development
Extension of the scuffing model to other materials– Non-ferrous materials: Cu, Al, Ti alloys– Ceramic material: single and polycrystalline – Thin film coatings
Incorporate other material behavior into a comprehensive model – Fracture– Phase transformation
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Technological Implications
Pathway to select and/or develop materials for high power density components and systems.– Major impact on vehicle efficiency– There are other material requirements for high power density
Predict scuffing resistance based on material properties and behavior.– Facilitate efficient design of new systems– Effective scuffing prevention strategy
• Role of run-in, lubricant formulation, surface modification ……
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Industrial Collaboration
Shear instability model been used for Caterpillar for scuffing prediction and modeling in component design
ContactAnalysis
Test Conditionsload /speed /geometry
3D Topography Contact Stress
Near Surface Shear Stress
Near Surface Shear Strain
Material Physical Properties
Shear Strain > γcr
Critical Strain γcr
Scuffing
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Project Goals and Structure
Near-surface-material dynamicchanges: - scuffing
Boundary film formation and loss rate: - APS, other tools
Basic mechanism of failureProperties of boundary films
Role of surface modification:- coatings
Models for film formation and behavior
Integrate both elements with EHD to formulate failure/performance prediction methodology
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X-ray as a surface characterization tool
Various x-ray based, non-vacuum techniques can be used to characterize the surface layer of materials with a boundary films – Reflectivity (XRR) – Can determine film thickness, roughness and
density of surface films– Diffraction (XRD) – Can determine the structure (xtalline or
amorphous), grain size, stress state• Glancing or grazing incident diffraction (GIXD)
– Fluorescence (XRF) – Can determine chemical composition of films – similar to EDAX in SEM
– Absorption Near Edge Structure (XANES) – Can determine chemical state of elements in the film
– Spectromicroscopy (XSM)– Others
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Our Approach to Tribofilms Chemical Analysis
Tribofilms form from additives, oil, surface material, and operation environmentUsual study Approaches:– Chemistry and modeling– Post-cleaning analysis
Our approach: – In-situ X-rays in and out,
nondestructively– Post cleaning analysis
Diffraction
Reflectivity
Fluorescence
Oil
Steel
Oxide
Phosphate
A typical sample
X-rays in and out
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Optical Microscopy of Tribo films
Tribo chemical films are not continuously smooth, but patchy– Spatial variability in
composition and properties
X-ray analysis will provide aggregate information
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Tribofilms: data and simulation
Simultaneous high-resolution fluorescence and reflectivity
High concentration of Zn on the film surface
Modeled self-consistently
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Incident angle θ, degrees
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Tribofilms: Chlorine for Extreme PressureModel formulated lubricant: chloroform in polyalphaolefin
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Shallow penetrationDeep penetration
Inte
nsity
2θ, degrees, λ = 1.2362 nm
FeCl2
FeCl2
FeCl3
Optical micrograph of surface XRD
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In-Situ Analysis
X-ray Accessible Tribotester construction completedExisting tribotester and X-ray detectorNew X-ray source Will give quantitative Zn/area during a tribotestFormation and loss rates
Based on: J. Hershberger, O. O. Ajayi, G. R. Fenske, Tribology Transactions 46 (4), 2003, 550-555, and: J. Hershberger, O. O. Ajayi, G. R. Fenske, Tribology International 38 (3), 2005, 299-303.
Schematic top view
Load
velocity
Incoming beam
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Preliminary Test Results
Test conducted with 52100 steel ball sliding on 1018 steel disc lubricated with POA with ZDDP and MoDTCadditives.
Simultaneous monitoring of the friction behavior and tribo films composition
Conduct tests with increasing contact severity; different additive composition; …
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Time, s
Optical micrograph of wear track
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Summary
Technical Accomplishments– Developed and validated a scuffing model based on material
properties• Foundation for development of materials for high power density systems• Efficient formulation of effective scuffing prevention strategies
– Developed X-ray based in-situ characterization technique for boundary at APS
• Used x-ray fluorescence, diffraction and reflectivity, • Designed and constructed an x-ray accessible tribo tester
We are on the way to developing durable and reliable low-friction components and systems for heavy vehicles.– Potential 5 – 10% overall efficiency improvement.
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Future PlansDesign and Development of Scuff-Resistant Materials/components– Needed for high power density tribological applications
– Formulate a comprehensive scuffing model that incorporates observed material behaviors – plasticity, cracking, phase transformation• Other materials – e.g. ceramics• Work on thin film coatings scuffing• Other surface modification
– Integrate materials, surface modifications (coatings), and lubricant for scuff resistance – system engineering approach
– Approach: Using the scuffing model design near surface tribological element on base materials that meet other structural requirements – strength, toughness, fatigue strength, ……. • High power density systems and subsystems – size and weight reduction
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Future PlansLubricated Contacts Surface Characterization and Optimization– In-situ tribochemical films structural characterization.
• Apply several X-ray-based surface analysis techniques available at APS.• Model film formation and loss rates.
– Mechanical properties and failure characterization of tribochemical films• Nano indentation and scratching technique• Electron microscopy and other imaging techniques.
– Evaluate the effects of tribochemical films on friction, wear, and scuffing. –implication for lubricant formulation
Integrate all the structural elements of surface lubrication to minimize friction and wear– materials, surface modification, lubricant basestockand additives.
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The End
Thank You !
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Supplemental slides -
More information – especially on details of test data and results
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3
Progression to Scuffing
Scuffing produced severely deformed surface layer (~ 20 μm) in fraction of second.
20 µm
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Phase transformation during scuffing
Phase labels:A = AusteniteF = Ferrite
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Sample
With synchrotron radiation at APS, X-ray diffraction analysis shows scuffing causes phase transformation, with formation of austenite
Data collected beamline 12-BM at APS
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Strain in Scuffed Samples - from peak broadening analysis
Plastic strain buildup in ferrite phase as a function of stage of scuffing and X-ray penetration depth
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Sample and penetration depth, μ m
* * * *small grain size
Experiment: Jeff Hershberger, ANLPerformed on beamline 12-BM at APS
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Surface Distress Analytical Toolkit
Physics-based Approach (SDAT)
Performance Analysis
Failure Prediction
Material Failure CriteriaMixed Lubrication
Module
Contact Temperature Module
Micro Contact Module
• Film Thickness• Pressure• Friction• Temperature• Subsurface Stress
• Contact Fatigue• Scuffing• Micropitting• ……
• Surface Texture• Residual Stresses• Thin Film Coatings• Physics-based
Failure Criteria
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Boundary Films Characterization
Squeeze films in oil:Analyze with XRD
Surfacetribofilms:
Analyze withXRF, XRR,
XRD
Near-surfacedeformation:
Analyze with XRD
Ba ll
Fla t
Oil
Using the APS to analyze boundary lubrication
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Tribofilms: Thermal and mechanical ZDDP
Quantitative Zn areal density on surface
Showed differences between films made thermally and mechanically
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ZDDP Concentration
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AFM of Tribofilm
Polished steel sample worn in commercial oil and solvent-rinsed.
Underlying steel polish
Raised areas of tribofilm deposit
Sample and data: J. Hershberger
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Tribofilms: XANES results
Cylinder linersTwo penetration depthsBonding state of atomWell-established technique, now done without rinsing
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Iron
Zinc
Zinc: bonded to oxygen and sulfur (not phosphorus)Iron: Best described as FeO. Differences with depth.