S.K. Biswas

Friction and wear of PTFE — a review

Polytetrafluoroethylene (PTFE) is an important engineering material. When rubbed or slid against a hard surface, PTFE exhibits a low coefficient of friction but a high rate of wear. These unique properties of the polymer have encouraged many mechanistic and physical examinations of the processes involved in the friction and wear of this polymer. A section of such work carried out over the past 30 years is reviewed here. When rubbed against a hard surface, the PTFE chain undergoes scission, creating active groups which chemically react with the counterface. This results in strong adhesion and a coherent transfer film. Further interaction between the bulk polymer and the transfer film gives rise to anisotropic deformation of the unit cell, which results in closeness of adjacent chains and easy shear between chains. Sliding brings about growth in as well as reorientation of crystallites situated in a very thin subsurface region of the bulk polymer. Such structural rearrangement facilitates the joining of adjacent aligned crystallites to form films and ribbons which emerge as debris.

Wear and seizure of binary Al-Si alloys

The wear and seizure behaviour of binary Al-Si alloys containing up to 23% Si has been investigated in sliding against a hard steel counterface by continuous loading experiments carried out in a pin-on-disc machine. Addition of silicon to pure aluminium improves wear and seizure resistance. The wear characteristics of alloys containing 7-17% Si, when considered as a function of load, exhibit distinct mild wear, severe wear and seizure regimes. Mild wear is characterised by the in situ formation of a protective iron-rich compacted layer. The severe wear is initiated when the protective layer is removed as a result of subsurface flow. On further increment of load this leads to seizure. Based on morphological observations in SEM, a qualitative model has been proposed for the wear behaviour of this group of alloys. An alloy containing 23% Si exhibits only mild and severe wear regimes and does not show any seizure within the present experimental limits. The alloy has low thermal conductivity and is prone to plastic flow instabilities as observed in compression tests. Because of these factors, the critical contact temperature required for seizure is not attained under the test conditions.

Dry wear of al-graphite particle composites

Under lubricated conditions, Al-graphite particle composite is a good antiseizure bearing and antifriction material possessing properties which inhibit excessive temperature rise in bearings. The present study characterizes the dry wear properties of the composite. The dry wear characteristics of the Al-(2.7%–5.7% graphite particle) (50–200μm) composite were found to deteriorate with the addition of graphite, load and sliding distance. Both micro structural and microhardness studies of the worn subsurfaces and analysis of wear debris show that the reductions in strength and ductility of the composite due to graphite addition are the most likely causes of deterioration in the wear properties of the composite.

Characterization of dry sliding wear of Al---Si alloys

Controversy exists in the published literature as to the effect of silicon content and pressure on the dry sliding wear of Al---Si alloys. The present paper attempts to clarify the question by reporting a statistical analysis of data obtained from factorially designed experiments conducted on a pinon-disc machine in the pressure range 0.105–1.733 MPa and speed range 0.19–0.94 m s−1. Under these conditions it was found that, in the range 4–24 wt.% Si, wear of binary unmodified alloys does not significantly differ between the alloys. However, it is significantly less than that corresponding to an alloy containing no silicon. The effect of pressure on wear rate was found to be linear and monotonie and, over the narrow range of speeds used, the wear rate was found to be unaffected by speed. The coefficient of friction was found to be insensitive to variations in silicon content, pressure and speed.

Some mechanisms of tribofilm formation in metal/metal and ceramic/metal sliding interactions

Tribological interaction often generates new structures and materials which form the interface between the sliding pair. The new material designated tribofilm here may be protective or tribologically deleterious. The tribofilm plays a major role in determining the friction and wear of the interaction. Here, we give three examples: mechanically mixed, chemically generated and thermally activated, of tribofilms formed in three different tribological systems and speculate on the mechanism of their formation.

Scanning electron microscopy study of worn Al-Si alloy surfaces

A pin-on-disc machine was used to wear Al-Si alloy pins under dry conditions. Unmodified and modified binary alloys and commercial multi-component alloys were tested. The surfaces of the worn alloys were examined by scanning electron microscopy to identify distinct topographical features to aid elucidation of the mechanisms of wear.

Mechanism of seizure of aluminium-silicon alloys dry sliding against steel

A steel ball was slid on aluminium-silicon alloys at different temperatures. After the coefficient of friction had been measured, the surface shear stress was deconvoluted using a two-term model of friction. The ratio of surface shear stress to bulk hardness was calculated as a function of temperature, silicon content and alloying additions. These results are qualitatively similar to those recorded for pre-seizure specimens slid against an En24 disc in a pin-on-disc machine. This similarity, when viewed in the context of the phenomenon of bulk shear, provides a model for seizure of these alloys.

Nature of contact deformation of TiN films on steel

Nanoindentation experiments were carried out on a columnar ∼1.5-m-thick TiN film on steel using a conical indenter with a 5-m tip radius. Microstructural examination of the contact zone indicates that after initial elastic deformation, the deformation mechanism of the TiN is dominated by shear fracture at inter-columnar grain boundaries of the TiN film. A simple model is proposed whereby the applied load is partitioned between a deforming TiN annulus and a central expanding cavit yi n the steel substrate. It is possible to obtain a good fit to the experimental load–displacement curves with only one adjustable parameter, namely the inter-columnar shear fracture stress of the TiN film. The implication of results in the context of the performance of TiN films in service is also discussed.

Hardness of a surface containing uniformly spaced pyramidal asperities

Pyramidal asperities of different apical angle were machined on a flat copper surface. Hardness was estimated from the load–displacement graphs obtained by pressing a spherical rigid indenter onto the asperities. The variation of hardness with apical angle and pitch was recorded with a view to contributing to the development of a general framework for relating measured hardness to the surface roughness.

Wear characteristics and bearing performance of aluminium-mica particulate composite material

Some tribological properties of a mica-dispersed Al-4%Cu-1.5%Mg alloy cast by a conventional foundry technique are reported. The effect of mica dispersion on the wear rate and journal bearing performance of the matrix alloy was studied under different pressures and under different interface friction conditions. The dispersion of mica was found (a) to increase the wear rate of the base alloy, (b) to decrease the temperature rise during wear and (c) to improve the ability of the alloy to resist seizure.