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At least 451 records · Page 25

Friction reduction for engine components

The present invention relates to techniques for lowering friction between moving surfaces of, for example, an internal combustion engine. Friction reduction is achieved by adding texture modifications to surfaces that come in contact with each other. Texture modifications that reduce friction in accordance with the present invention include dimples of varying geometries and depths ion the surfaces of components. The present invention also relates to the fabrication technique for applying the texture to the surfaces. In another embodiment, the patterned soft mask is applied onto a large surface (flat or curved including cylindrical rollers surfaces) to be followed by electrochemical etching to imprint the textures onto the component And, in another embodiment, a diamond-like-carbon (DLC) film may be applied to the turbine component to also reduce friction.

Hsu, Stephen M.↗

Low friction coatings

A low friction, wear-resistant surface operable at high temperatures and high loads with a low coefficient of friction including boron nitride and graphene-oxide on steel or nanodiamonds and graphene on aluminum. The low friction, wear-resistant surface remains with a coefficient of friction in the superlubric regime at temperatures in between about 200° C. and 970° C.

36 MATERIALS SCIENCE↗

Oil-Soluble Polymer Brush Grafted Nanoparticles as Effective Lubricant Additives for Friction and Wear Reduction

Developments of high performance lubricants are driven by increasingly growing industrial demands and environmental concerns. We demonstrate oil-soluble polymer brush-grafted inorganic nanoparticles (hairy NPs) as highly effective lubricant additives for friction and wear reduction. A series of oil-miscible poly(lauryl methacrylate) brush-grafted silica and titania NPs were synthesized by surface-initiated atom transfer radical polymerization. Moreover, these hairy NPs showed exceptional stability in poly(alphaolefin) (PAO) base oil; no change in transparency was observed after being kept at -20, 22, and 100°C for ≥55 days. High-contact stress ball-on-flat reciprocating sliding tribological tests at 100°C showed that addition of 1 wt% of hairy NPs into PAO led to significant reductions in coefficient of friction (up to ≈40%) and wear volume (up to ≈90%). The excellent lubricating properties of hairy NPs were further elucidated by the characterization of the tribofilm formed on the flat. These hairy NPs represent a new type of lubricating oil additives with high efficiency in friction and wear reduction.

36 MATERIALS SCIENCE↗

The Sliding Wear and Friction Behavior of M50-Graphene Self-Lubricating Composites Prepared by Laser Additive Manufacturing at Elevated Temperature

M50 steel is widely applied to manufacture aircraft bearings where service lives are mainly determined by the friction and wear behaviors. The main purpose of this study is to investigate the tribological behaviors and wear mechanisms of M50-1.5 wt.% graphene composites (MGC) prepared by laser additive manufacturing (LAM) (MGC-LAM) sliding against Si{sub 3}N{sub 4} ball from 25 to 550 °C at 18 N–0.2 m/s. XRD, EPMA, FESEM, and EDS mapping were conducted to understand the major mechanisms leading to the improvement in the sliding behavior of MGC-LAM. The results indicated that MGC-LAM showed the excellent friction and wear performance at 25-550 °C for the lower friction coefficient of 0.16-0.52 and less wear rate of 6.1-9.5 × 10{sup −7} mm{sup 3} N{sup −1} m{sup −1}. Especially at 350 °C, MGC-LAM obtained the best tribological performance (0.16, 6.1 × 10{sup −7}mm{sup 3} N{sup −1} m{sup −1}). It was attributed to the dense coral-like microstructure, as well as the formed surface lubricating structure which is composed of the upper uniform lubricating film with massive graphene and the underneath compacted layer.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

The Sliding Wear and Frictional Behavior of M50-10 wt.%(Sn-Ag-Cu) Self-Lubricating Materials at Elevated Temperatures

As the main steel used in the aero-engine main shaft bearings, the tribological properties of M50 can directly affect the performance of aero-engine. The purpose of this study is to design the reasonable composition of Sn-Ag-Cu alloy and investigate the wear mechanisms of M50-10 wt.%(Sn-Ag-Cu) composites (MSACC) prepared by SPS sliding against Si{sub 3}N{sub 4} ball from 25 to 550 °C at 12 N-0.25 m/s. XRD, EPMA, FESEM and EDS mappings are conducted to understand the major mechanisms leading to the improvement in the sliding behavior of MSACC. The results indicate that MSACC with different specifications of Sn-Ag-Cu alloy shows excellent friction and wear properties from 25 to 550 °C compared to M50. M50-10 wt.%(50Sn40Ag10Cu) (MSACC-2) shows the distinguished tribological performance for the lower friction coefficients of 0.22-0.61 and less wear rates of 1.7-4.1 × 10{sup −6} mm{sup 3} N{sup −1} m{sup −1}, which is attributed to the formed excellent lubricating structure consisting of the lubricating film with massive Sn-Ag-Cu alloy and intermetallic compounds formed during the friction process, as well as the underneath mixed layer who can well support the lubricating film due to the good intersolubility between the designed Sn-Ag-Cu alloy and M50 (Fe).

36 MATERIALS SCIENCE↗

Analysis of integrity and microstructure of linear friction welded Waspaloy

Nickel-base superalloy, Waspaloy, was linear friction welded (LFWed) under different axial shortening conditions of 2.0, 3.4, and 4.6 mm. The tensile properties and microhardness of the weldments were investigated in the as-LFWed condition and compared with those in the post-weld heat treated (PWHTed) condition. Mechanical properties were related to microstructures following examination by optical microscopy, high resolution scanning electron microscopy, and electron backscatter diffraction (EBSD). Analyses of the EBSD results in terms of the misorientation angle distribution, which represents the stored energy, were performed. In the as-LFWed condition, the yield strength (YS) and ultimate tensile strength (UTS) increased with axial shortening due to greater expulsion of the softened interfacial material toward the periphery as flash. In contrast, with increasing axial shortening the total elongation initially remained constant and then decreased. This was also related to the expulsion of the softened interfacial material into the bifurcated flash. Extensive dissolution of the strengthening phase (γ′) in the weld area during linear friction welding (LFW) contributed to the lower YS and UTS in the as-welded condition compared to the PWHTed condition where the γ′ particles were recovered. After performing post-weld heat treatment (PWHT), the total elongation improved due to the relaxation of stored energy and grain growth in the thermomechanically affected zone (TMAZ). - Highlights: • Tensile property and microstructure in Waspaloy linear friction welds were studied. • Yield strength and ultimate tensile strength increased with axial shortening. • Elongation initially remained constant and then decreased with axial shortening. • Post-weld heat treat recovered dissolved γ′ particles and increased weld strength. • Stored energy relaxation during post-weld heat treatment improved weld elongation.

36 MATERIALS SCIENCE↗

Friction and Wear Reduction Mechanism of Polyalkylene Glycol-Based Engine Oils

Polyalkylene glycols (PAG) have been explored as a possible base stock for engine oil formulation. The friction, wear, and load-carrying capacity of five different PAG chemistries were evaluated either as a base stock or as formulated oils in pure sliding and sliding-rolling conditions using various laboratory bench test rigs operating under boundary and mixed lubrication regimes. The results were compared against GF-5 SAE 5W-20 and a mineral-based oil. The wear surfaces were also characterized using various surface-sensitive techniques for analysis of tribofilms to understand the mechanism of friction reduction. The results indicated that PAG oils show lower friction/traction coefficients and improved load-carrying capability, depending on the formulation, than those of the GF-5 SAE 5W-20 and mineral-based oil. The adsorption of PAG molecules on the surface appeared to be responsible for the lower friction characteristics.

AES↗

Advances in Dissimilar Metals Joining through Temperature Control of Friction Stir Welding

Lightweighting of vehicles and portable structures is an important undertaking. Multi-material design is required to achieve conflicting design targets such as cost, stiffness, and weight. Friction stir welding (FSW) variants, such as friction stir dovetailing and friction stir scribe, are enabling technologies for joining of dissimilar metals. This work shows that FSW variants are capable of joining aluminum to steel. Characteristics of metallurgical bonding at the dissimilar material interface are strongly affected by weld temperature. Control of FSW process temperature enables metallurgical bonding with suppressed formation of intermetallics at the dissimilar material interface resulting in improved mechanical properties relative to competing techniques. Temperature control is a powerful tool for process development and to ensure weld quality of dissimilar material welds.

Aluminum to Steel Joining, Friction stir welding, ↗

Friction Stir Processed Repair Welding of Dry Storage Canisters and Mitigation Strategies: Effect of Engineered Barrier Layer on Environmental Degradation

The proposed project aims to develop a friction sir based repair technique to heal cracks of stainless steel dry storage canisters (DSCs), created by the effect of stress corrosion cracking (SCC). In real service conditions, the welded parts of the canisters become prone to SCC under exposure to aggressive chemical environment. The focus of the project is on developing a mitigation strategy that can be implemented for countering SCC in DSCs following a two-pronged approach: (i) apply friction stir processing (FSP) as a crack repair technique while creating compressive residual stresses at the canister material surface, thus improving resistance against SCC; (ii) add molybdenum and/or nitrogen by friction stir based alloying process to create compositions that improve pitting resistance and thus enhance resistance against SCC. The specific project objectives are listed below: • Investigate FSW of 304L SS a potential repair welding technique of dry storage canisters; • Optimize the FSW parameters to introduce surface compressive stress profiles in the weldments; • Develop a FSP method to surface alloy the 304L with nitrogen and Mo by adding CrN and Mo powders; • Evaluate the surface compressive residual stress profile during FSW and FSP processes; • Evaluate the localized corrosion resistance of the FSW and FSP samples as a function of temperature, chloride concentration, and surface alloy composition; • Evaluate the SCC behavior of the FSW and FSP samples as a function of stress, chloride concentration, and temperature at different surface chemistries and induced residual stress profiles.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Synchrotron Radiation in Analysis of Structural Transformations Under Friction Conditions of Carbon Steel

The paper presents results of the structural transformations in the surface of carbon steel specimens during the first tens of cycles of the friction loading with a hard-alloy indenter. The widespread type AISI 1020 carbon steel is used in the experiments which are carried out on the Microfocus Beamline ID13 of the European Synchrotron Radiation Facility. The experimental setup is designed to record the diffraction patterns during the friction. It is shown that at the initial stage of friction, the diffraction maxima significantly broaden due to the defect accumulation in the crystal lattice and, as a consequence, the growth in elastic micro-distortions and the size reduction of the coherent scattering areas. A serious increase is observed in the intensity of reflection from planes of {110} family due to the formation of the respective texture in the surface layers of steel specimens. A non-destructive method is used to detect the diffraction patterns both for non-moving and moving specimens.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Friction Stir Welding of Dissimilar Al/Al and Al/Non-Al Alloys: A Review

Friction stir welding is a solid-state welding technique that has many advantages over traditional fusion welding, and has been widely adopted in the aerospace and automotive industries. This article reviews research developments in friction stir welding of dissimilar alloys systems, including combinations of aluminum alloys with Mg alloys, Cu, and steel. Microstructural evolution, hardness, tensile and fatigue properties, residual stresses, and corrosion behavior of dissimilar welds will be reported. The effects of processing parameters such as tool rotation and traverse speeds, tool position, material position, and tool geometry on the weld quality are also presented. Discussions on future research directions in friction stir welding will also be provided in the context of existing literature and future high-integrity applications.

36 MATERIALS SCIENCE↗

Modeling of the Heat-Affected and Thermomechanically Affected Zones in a Ti-6Al-4V Inertia Friction Weld

Inertia friction welding has been used across the aerospace, automotive, and power-generation industries for the fabrication of complex axisymmetric components for over forty years. The process involves one axisymmetric piece being held stationary and another piece being brought into contact set to rotate about its axis of symmetry by a flywheel with the system under an applied load across the joint. Plasticization at the joint interface through the frictional heating sees the two pieces bond together. The titanium alloy Ti-6Al-4V has been widely studied for inertia welding applications. A successful selection of processing parameters (flywheel energy and mass, applied load) allows an inertia welding process which produces a very high-integrity weld, with a minimal heat-affected zone (HAZ) and thermomechanically affected zone (TMAZ), formed as a narrow band at the interface and extending further into the material. The width of this narrow band of heated material is dependent upon the process parameters used. A series of experimental inertia friction welds were performed using Ti-6Al-4V, and a finite element (FE) modeling framework was developed using the FE code Deform in order to predict the widths of the HAZ and TMAZ at the weld interface. The experimentally observed HAZ boundaries were correlated with the thermal fields from the FE model, while TMAZ boundaries were correlated with the Von Mises plastic strain fields.

42 ENGINEERING↗

Friction and Wear Properties of CrSiCN/SiC Tribopairs in Water Lubrication

CrSiCN coatings (3.4 at.% Si) were prepared on 316L stainless steels using unbalanced magnetron sputtering. According to the analysis results of x-ray diffractometer and x-ray photoelectrons spectroscopy, silicon in CrSiCN coatings mainly presented in the amorphous forms of a-SiN, a-SiCN and a-SiC. The hardness and Young’s modulus of CrSiN coatings were 19.4 ± 0.6 and 306.1 ± 5.9 GPa, respectively. In addition, the ball-on-disk sliding tests of CrSiCN/SiC tribopairs were performed in distilled water at varying velocities (0.1-0.5 m/s) and loads (2-12 N). The friction coefficient of tribopairs presented a decreasing trend with respect to velocity at low applied loads (≤ 4 N). To be specific, the low friction coefficient of 0.05-0.14 accompanied with polished wear scar was obtained at high velocities and low loads. Finally, the wear mechanism map of CrSiCN/SiC tribopairs was proposed based on a combination of friction coefficient, wear scar morphology and wear rates of tribopairs.

36 MATERIALS SCIENCE↗

Tribo-corrosion and Albumin Attachment of Nitrogen Ion-Implanted CoCrMo Alloy During Friction Onset

In this paper, CoCrMo alloy surface was implanted with 100 keV nitrogen ions to modify it. Bovine serum albumin (BSA) adsorption and the initial behavior of tribo-corrosion in the simulated system were studied. Nitrogen ion implantation can promote BSA dynamic adsorption due to the change of friction and wear mechanisms. From the tribo-corrosion test results, the open circuit potential (OCP) increased to about 0.6 V and the coefficient of friction (COF) decreased to about 0.2 for the nitrogen ion-implanted CoCrMo compared with the untreated sample before the modified layer failure. The point when the open circuit potential and the coefficient of friction changed during long wear time (1, 2 and 4 h) is considered the sign of the worn through modified layer. Then, the OCP of the implanted sample rose by 0.3 V compared with the untreated sample, and the COF remained at around 0.3, which is lower compared with the COF of untreated sample after the modified layer has been worn through. Thus, nitrogen ion implantation not only improved wear and corrosion resistance of the CoCrMo alloy, but also promoted BSA adsorption on the CoCrMo alloy surface, which effectively reduced the wear volume and metal ions release.

36 MATERIALS SCIENCE↗

Microstructure and Mechanical Behavior of Friction Stir-Welded Sc-Modified Al-Zn-Mg Alloys Made Using Different Base Metal Tempers

The microstructure and property of friction stir weld joints of a Sc-modified Al-Zn-Mg alloy developed using base metal in hot-rolled (HR) and T6 temper were studied and compared in this work. The results showed that the microstructure and property exhibited significant difference between the two friction stir weld joints. The weld efficiency of the FSW joint developed using base metal in HR condition is over 90%, while that of the FSW joint developed using base metal in T6 condition is only 70%. The hardness of the weld nugget of HR joint is obviously higher than that of the weld nugget of T6 joint, due to the different changes in the original precipitates during the friction stir welding process. The strengthening mechanism in different zones of the two FSW joints was discussed to examine the microstructure–properties relationship, and the main difference of the strengthening mechanism between the two FSW joints was revealed.

36 MATERIALS SCIENCE↗

Investigation of Raster Pattern Spacing and Direction for Friction Stir Additive Manufacturing of Al-5083

Friction stir additive manufacturing (FSAM) is a sheet-lamination based additive manufacturing technique. In addition to the traditional factors that govern the friction stir process-structure-property relationship, the processing history is convoluted by the in-plane raster pattern and repeated thermal cycling from subsequent layers. This can lead to complex thermal gradients within the workpiece and reprocessing of material. Here, this work aims to understand the impact of raster pattern spacing and direction on the microstructure and properties during friction stir additive manufacturing of Al-5083. Control of the raster spacing can lead to an increase in hardness of up to 18% from the base material and defect-free joining. These results are then directly demonstrated at the component-scale for FSAM of Al-5083.

36 MATERIALS SCIENCE↗

Pitting behavior of friction stir repair-welded 304L stainless steel in 3.5% NaCl solution at room temperature: role of grain and defect structures

Stainless steel (SS) canisters used for storing spent nuclear waste are prone to chloride-induced stress corrosion cracking. Friction stir welding (FSW), being a low heat input process, can be used for repair welding of these canisters. In this study, an artificial crack was introduced on the 304L SS coupons by an electric discharge machining process. The artificial crack was repair-welded by FSW by maintaining the tool temperature a constant at two levels (725 and 825 °C). Friction stirring significantly reduced the grain size of the stirred zone (SZ) from about 47 to 2–4 μm. The fraction of low-angle grain boundaries increased in the SZ from 2 to 37–43%. Here, on the other hand, the fraction of special grain boundaries (Σ3 and Σ9) that was ~ 50% in the base metal reduced to < 10% in the SZ. During friction stirring, the oxide layer of artificial crack was broken and aligned to form a spiral defect called lazy-S structure. All these microstructural changes affected the corrosion behavior of the FSW specimens when tested in 3.5% NaCl at room temperature using cyclic polarization, chronoamperometry, and electrochemical impedance spectroscopy. The FSW specimens showed lower polarization resistance and lower transpassive potential than those of the base metal specimens. However, the pitting protection potentials of the FSW specimens were higher than that of the base metal. The pitting behavior of the FSW specimens was influenced more by the preferential attack on the lazy-S region than by passive film breakdown. The flat band potentials of the passive film formed on the FSW specimens were more positive than that of base metal. The charge carrier density of passive film formed on the FSW specimens was higher than that of the base metal. The higher fraction of low-angle grain boundaries present in the FSW specimens could supply more number of misorientation dislocations at the metal/film interface which could form anion vacancies by a climb process leading to formation of oxide at these locations without stressing the substrate. Therefore, low-angle boundaries are considered helpful for formation of stress-free passive films that will be highly stable and enhance both pitting and stress corrosion cracking resistance.

Dry storage canister↗

Dynamic simulation of CO 2 -injection-induced fault rupture with slip-rate dependent friction coefficient

It is known that poro-elastic stress and effective stress reduction associated with deep underground fluid injection can potentially trigger shear rupture along pre-existing faults. We modeled an idealized CO 2 injection scenario, to assess the effects on faults in the first phase of a generic CO 2 aquifer storage operation. We used coupled multiphase fluid flow and geomechanical numerical modeling to evaluate the stress and pressure perturbations induced by fluid injection and the response of a nearby normal fault. Slip-rate dependent friction and inertial effects have been taken into account during rupture. Contact elements have been used to take into account the frictional behavior of the rupture plane. We investigated different scenarios of injection rate to induce rupture on the fault, employing various fault rheologies. Published laboratory data on CO 2 -saturated intact and crushed rock samples, representative of a potential target aquifer, sealing formation and fault gouge, have been used to define a scenario where different fault rheologies apply at different depths. Nucleation of fault rupture takes place at the bottom of the reservoir, in agreement with analytical poro-elastic stress calculations, depending on injection-induced reservoir inflation and the tectonic stress scenario. For the stress state considered here, the first triggered rupture always produces the largest rupture length and slip magnitude, both of which correlate with the fault rheology. Velocity weakening produces larger ruptures and generates larger magnitude seismic events. Heterogeneous faults have been considered including velocity-weakening or velocity strengthening sections inside and below the aquifer, with the upper sections being velocity-neutral. Nucleation of rupture in a velocity-strengthening section results in a limited rupture extension, both in terms of maximum slip and rupture length. For a heterogeneous fault with nucleation in a velocity-weakening section, the rupture may propagate into the overlying velocity-neutral section, if the extent of velocity-weakening and associated friction drop are large enough.

58 GEOSCIENCES↗