The anti-wear and anti-seizure performance and action mechanisms of zinc dithiophosphate (ZDDP) have been investigated under reciprocating pure sliding conditions to simulate piston ring and cylinder liner assembly, using new techniques. The Mini Traction Machine–Space Layer Imaging is a useful method for monitoring tribofilm formation by ZDDPs. However, tests are generally carried out in mixed sliding–rolling conditions and ZDDP film formation in reciprocating pure sliding conditions is rarely investigated. In this paper, the authors describe an investigation of ZDDP film formation in stationary ball on reciprocating disc pure sliding conditions and compare the results to those obtained in unidirectional pure sliding conditions. In unidirectional pure sliding conditions, the worn area on the ball expands with test time. By contrast, in reciprocating pure sliding conditions, tribofilm forms on the stationary ball and no significant damage occurs. In the initial tribofilm formation under reciprocating pure sliding conditions, solid particulate tribofilm with a high concentration of S forms initially in the contact area and subsequently breaks up. During further rubbing, a Zn- and P-rich tribofilm forms on the comminuted sulphur-rich tribofilm and also the area where the initial tribofilm was removed.

/pdf/the-tribofilm-formation-of-zddp-under-reciprocating-pure-3sxxw9w6q6.pdf

The Tribofilm Formation of ZDDP Under Reciprocating Pure Sliding Conditions

Influence of mass temperature on gear scuffing

Scuffing is a surface failure mode that occurs in sliding–rolling contacts subjected to high loads and high sliding speeds, such as those in gears and cam-followers. Owing to its sudden onset, rapid progression and dependence on both fluid and boundary lubricant films, scuffing is difficult to study in a repeatable manner. This paper describes further development of a recently proposed scuffing test method based on contra-rotation, its extension to higher loads using a new experimental set-up and its application to study the onset of scuffing with a selection of model and fully-formulated oils. The method employs two surfaces moving in opposite directions under rolling–sliding conditions, with a fixed load and step-wise increasing sliding speed. By decoupling the entrainment and sliding speeds, the method allows the effects of lubricant formulation on scuffing performance to be isolated from the influence of viscosity. The approach achieves high sliding speeds in parallel with low entrainment speeds, while minimising the undesirable effects of surface wear and frictional heating. The proposed test is relatively fast and economical, with total test time of about 30 min including specimen cleaning and set-up. Results show that the newly implemented modifications have improved the repeatability of the test method, so that the number of repeat tests required for reliable oil ranking results is minimal. Tests with model and fully-formulated oils show that the onset of scuffing is characterised by a sharp and unrecoverable increase in friction and accompanied by the destruction of any boundary films. All tests show that the relationship load × speedn = constant holds at scuffing, with the exact value of the exponent n being dependent on the oil formulation. Additivised oils were shown to have enhanced scuffing resistance, which arises from their ability to postpone the uncontrollable rise in friction to higher sliding speeds. Finally, the critical maximum contact temperature scuffing criterion was shown to predict the onset of scuffing in our tests better than the frictional power intensity criterion.

/pdf/the-development-and-application-of-a-scuffing-test-based-on-rl6sd5w1yr.pdf

The Development and Application of a Scuffing Test Based on Contra-rotation

An experimental approach for investigating scuffing initiation due to overload cycles with a twin-disc test device

In order to reduce vehicle weight and thus improve fuel economy, aluminium (Al) alloys have been increasingly adopted as contact surfaces such as piston skirts and cylinder liners in current engines. In general, hypereutectic Al–Si alloys are used, in which hard silicon grains are embedded in a softer Al–Si single phase matrix. It is reported that after rubbing, the matrix is removed to leave silicon grains protruding from the surface. However, the response of the counter-surface by these silicon grains is rarely investigated. In this study, mini traction machine–space layer imaging (MTM–SLIM) has been used to monitor tribofilm formation in situ and investigate the evolution of both surfaces in the contact of a steel ball on an Al–Si disc lubricated by ZDDP solution. In low-load conditions, the top layer of aluminium on the Al–Si disc is removed physically to leave silicon grains protruding from the surface, while ZDDP tribofilm pads are formed mainly on the grains. On the counter-surface (steel ball), ZDDP tribofilms are formed and build up with no wear scars. In high-load conditions, deep gaps are observed to form initially round the silicon grains on the disc. During rubbing, these become shallower, while the silicon grains start to protrude. On the steel ball, ZDDP tribofilm is generated initially over the whole rubbing track, but then the tribofilm in the middle of the track is almost completely removed by rubbing against the protruding silicon grains. Wear of the underlying steel surface then ensues.

https://link.springer.com/content/pdf/10.1007%2Fs11249-017-0915-8.pdf

The Influence of Aluminium–Silicon Alloy on ZDDP Tribofilm Formation on the Counter-Surface

A new scuffing test using contra-rotation

The measurement of lubricant film thickness under elastohydrodynamic (EHL) contact conditions is well established and a variety of experimental techniques have been used, the most accurate and widely used of which is optical interferometry. This lends itself particularly well to the study of the all-important mixed and boundary regimes, since the films are of the same order of magnitude as the wavelength of light. The vast majority of these studies have been made under pure rolling conditions, since the necessary optical coatings preclude the use of high sliding speeds within the critical thin fluid film regime. These conditions are however precisely those required to activate ZDDPs and other antiwear additives, making accurate ‘in situ’ optical studies of additive film build-up difficult. A modification to the existing MTM (mini-traction machine) has allowed steel on steel contacts to be run under high sliding speed conditions, thereby allowing antiwear additive reactions to occur. By optically measuring the film thickness of these reaction films as they form, in tandem with friction measurements, a full picture of both friction and reaction film build-up can be made. Using a novel LED (light emitting diode) light source and accurate calibration procedures, the film thickness of the whole contact area can be measured down to a few nanometres. This paper presents a study of the behaviour of standard additive combinations under realistic operating conditions and describes the rig in detail.© 2007 ASME

A Study of Antiwear Additive Film Build Up Using the MTM (Mini-Traction Machine)

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A new scuffing test using contra-rotation

A Study of Antiwear Additive Film Build Up Using the MTM (Mini-Traction Machine)