International Conference on Metallurgical Coatings and Thin Films
Prediction of DLC friction lifetime
based on a local Archard factor
density approach
F. ALKELAE , S. FOUVRY
April 29 May 3, 2013
San Diego, CA, USA
SUMMARY
Experimental device
Material used
Experiments performed
Expertises performed
Friction analysis
Wear analysis
Endurance analysis based on Archard local energy density
Experimental layout
Q*,*
0g
Experimental device schema
Materials data.
Fretting loop
Composition (Wt %)
Young Modulus
(GPa)
52100 Chromium steel 97% Fe,1.45% Cr, 0.98% C, 210
0.35% Mn
DCY (DLC)
81.35% C, 16.92% W, 1.73% 364
Cr
P is kept constant
=>
Materials Data.
Plotting Q = f() : fretting loop
Q and are recorded
3
Work conditions and material used
52100 steel ball
DLC coating
52100 steel substrate
Configuration adopted
Conditions
Valeurs
P (N)
g (m)
50
pmax (Mpa)
430
F (Hz)
25
T (C)
20
RH (%)
29
Experimental conditions
Two families:
-Hydrogen free
-Hydrogen content
DLCs
DLC categories
Friction analysis
1.2
1.2
52100/52100
1.0
0.8
0.6
0.4
0.2
DLC/52100
(I)
(II)
(III)
1
2
3
0.0
0.E+00
Friction coefficient
Friction coefficient
52100/52100
5
4
Friction criterion (th=0.3)
2.E+06
4.E+06
6.E+06
8.E+06
1.0
0.8
(I)
0.6
(II)
DLC/52100
0.4
0.2
Friction criterion (th=0.3)
0.0
1.E+02
Fretting cycles Nc
Linear representation of the
friction coefficient evolution
(III)
3
1.E+03
1.E+04
1.E+05
1.E+06
1.E+07
Fretting cycles Nc
Logarithmic representation of the
friction coefficient evolution
Abrupt decrease on the friction coefficient after sequence 2.
continuous increase on the friction coefficient after sequence 2 until stabilizing at almost the
52100/52100 friction coefficient.
Wear analysis
5
1
0.5mm
Plane DLC fretting scars
0.5mm
Ball 52100 fretting scars
Interrupted tests optical observations of the plane (above) and the ball
(bellow)
Wear analysis
3D profiles
500m
2D axial profiles
Surface
Coating thickness
1
-2m
3D profiles
3D associated to 2D profiles of different interrupted tests
Wear analysis
SEM
Cr
Fe
Si
SEM and EDX mapping of the plane fretting scar at different damage
sequences.
Wear analysis
plane fretting scar analysis
ball fretting scar analysis
(a) Central zone
CrC
(a) Central zone
(a)
(1)
Fe2O3+Fe3O4-ref
(a)
(b) DLC-ref
(b)
0
400
800
1200
1600
raman
shift
(cm-1)
400
800
1200
raman
shift
(cm-1)
1600
(a) Central zone (black area)
(b) External zone
(bright area)
(a) Central zone
(a)
(a)
(2)
Cr8O21(mixture of
CrO2 & Cr2O3)
DLC-ref
(b) DLC-ref
(b)
(b)
0
400
800
1200
1600
(cm-1)
(cm-1)
400
800
1200
1600
Fe2O3+Fe3O4-ref
(a) Central zone (bright)
CrC
(b) Black corona
CrC
(a)
(3)
(b)
(a) Central zone
(red area)
(a)
DLC-REF
(b) Central zone
(bright area)
DLC-ref
Fe2O3+Fe3O4-ref
FeCr2O4-ref.
(b)
0
400
800
1200
1600
(cm-1)
400
800
(a) Debris area CrC
(red)
(b)
(4)
(a) Central zone (bright)
(a)
(b) Debris (grey)
DLC-REF
FeCr2O4-ref.
400
800
1200
1600
(cm-1)
1200
1600
(cm-1)
(b) Central zone
Fe2O3+Fe3O4-ref
(a)
(b)
(cm-1)
0
400
800
1200
1600
Raman analysis of plane and sphere fretting scar at different stages of the fretting wear
damage
9
Wear analysis
_
= 0.4, Ra = 0.95m
_
= 0.2, Ra = 1.63m
Roughness and friction coefficient comparison between sequence 1 and 3.
Remarkable friction coefficient of a smooth surface ( = 0.95m) comparatively to a rough
surface ( = 1.63m)
=>
The polishing process is not the predominant parameter of the friction coefficient decrease from
sequence 1 to sequence 3 but rather the nature of the transfer layers.
10
Friction coefficient
Prediction of the interface endurance
Coating
failure
Friction faillure
th = 0.3
(period I)
(period III)
(period II)
Nc1
Nc2
Number of cycles
Schematization of the friction interface evolution considering the coeting failure
(Nc1) and the friction failure (Nc2)
Nc1: the sharp decrease from the 0.4 friction plateau to the 0.2 friction plateau.
Nc2: the friction faillure which is defined by a friction value _th =0.3.
11
Prediction of the interface endurance
1 000
900
100
Loading pressure pmax (MPa)
Sliding amplitude g ( m)
120
80
60
40
y = -3E-05x + 169.25
R = 0.9517
800
700
600
500
400
y = -6E-05x + 701.6
R = 0.815
300
200
20
100
0
0.0E+00
0
1.0E+06
2.0E+06
3.0E+06
4.0E+06
5.0E+06
6.0E+06
Friction endurance Nc2
Evolution of the friction endurance Nc2 as a
function of the sliding amplitude(P = 5N).
0.0E+00
1.0E+06
2.0E+06
3.0E+06
4.0E+06
5.0E+06
Friction endurance Nc2
Evolution of the friction endurance Nc2 as
a function of the contact pressure( =
50m).
The friction endurance seems to decrease while increasing the loading
pressure and the sliding amplitude.
12
Prediction of the interface endurance
Illustration of the
Hertzian approach
methodology
~
WH 2 pmax aH e 1 e 2 Arc sine
Pressure field illustration
1
2
Methodology of
computing the
simplified approach
~
WS 4 pmax g
Determination of the dissipated
local energy
The local dissipated energy analysis is conducted assuming Hertzian pressure field distribution.
The maximum Archard work density dissipated is situated at the center of the sphere/plane
interface (x = y = 0) following the Hertzian hypothesis
13
Prediction of the interface endurance
1.4E+05
1.8E+05
Nc2-dg=50m
/ pmax var
Nc2 g = 50m
/ pmax var
1.6E+05
Nc2 pmax = 430MPa/
g var
Nc2-pmax-430MPa
/ dg var
1.4E+05
1.2E+05
1.0E+05
8.0E+04
6.0E+04
4.0E+04
2.0E+04
0.0E+00
0.0E+00
1.0E+06
2.0E+06
3.0E+06
4.0E+06
5.0E+06
6.0E+06
Friction endurance Nc2
Evolution of the simplified Archard work
approximation as a function of the
friction endurance Nc2
DCY
/ pmax var
Nc : dg=50m
g = 50m
/p
max
var
Nc2: pmax=430
pmax = 430MPa/
g
DCY
MPa / dg var
var
Local Archard work density
WH(N.m/m2)
Local Archard work density
WS(N.m/m2)
2.0E+05
1.2E+05
1.0E+05
8.0E+04
6.0E+04
4.0E+04
2.0E+04
y = -3E-09x2 + 0.003x + 11700
R = 1
0.0E+00
0.0E+00
1.0E+06
2.0E+06
3.0E+06
4.0E+06
5.0E+06
6.0E+06
7.0E+06
Friction endurance Nc2
Evolution of the exact hertzian Archard
work approximation as a function of
the friction endurance Nc2
Large dispersion while using the simplified formulation especially for low endurance domain.
A good correlation obtained using the exact formulation which consider an elliptical distribution
of the contact pressure.
14
Prediction of the interface endurance
1.4E+05
Friction endurance
Local Archard work density
WH(N.m/m2)
1.2E+05
1.0E+05
8.0E+04
Coating endurance
6.0E+04
4.0E+04
Nc2-dg=50m
pmax var
Nc g =/ 50m
/ pmax var
Nc2-pmax-430MPa
/ dg var g var
Nc2 pmax = 430MPa/
Nc1-dg=50m
var / pmax var
Nc1 g =/ pmax
50m
Nc1 pmax = 430MPa/
Nc1-pmax-430MPa
/ dg var g var
2
2.0E+04
0.0E+00
0.0E+00
1.0E+06
2.0E+06
3.0E+06
4.0E+06
5.0E+06
6.0E+06
endurance Nc
Evolution of the applied Archard work density as a function of the coating
(Nc1) and the friction (Nc2) endurances
The coating endurance does not seem to be a function of the local Archard work density.
A good correlation between the friction endurance values represented as a function of the
local Archard parameter.
15
Conclusion
DLC coatings are very interesting palliatives for fretting wear applications thanks to their very low riction
coefficient and wear rate
Since the evolution of the friction coefficient is devided into three phases, Raman spectroscopy, SEM and
EDX have shown that the transition from the first plateau of = 0.4 to the second of = 0.2 is monitored
by the formation of lubricious layers of DLC and chromium carbide, right after a little stabilization at this
second plateau, a continuous increase of the friction coefficient take place until almost reaching the
friction value of 52100/52100 contact.
A local Archard work density parameter was used to quantify the durability of the coating, two
endurances were taking into account, Nc1 : the coating faillure and Nc2 : the the friction faillure.
Nc2 > Nc1
Exact formulation and simplified formulation were plotted versus the friction endurance. A
remarkable dispersion was observed using , whereas a single master curve was obtained modeling
thus the wear evolution with the exact formulation.
For the coating endurance a vertical curve was obtained which means that it is not a function of the local
Archard work.
Thank you for your
kind attention
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