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Under severe conditions, solid contacts take place even when parts are lubricated. Precise mathematical conditions are needed to describe the interior interface between fluid lubrication and solid-contact zones. In order to distinguish the conditions for this interface from conventional lubrication boundary conditions, they are named lubrication–contact interface conditions (LCICs). In this work, mathematical LCICs are derived with local flow continuity from the continuum mechanics point of view and pressure inequality across the interface. Numerical implementations are developed and tested with problems having simple geometries and configurations, and they are integrated into a new mixed/boundary elastohydrodynamic lubrication solver that uses a new method to determine solid-contact pressures. This solver is capable of capturing film thickness and pressure behaviors involving solid contacts.

We recently reported the use of cyclopropanecarboxylic acid (CPCa) as a model additive that can readily react under the combined effect of flash heating and stress in steel tribocontacts to form tribopolymers, along with marked improvement in tribological performance. In this paper, we present results of how chemical structural modification of CPCa may impact on the formation of tribopolymers and hence friction and wear properties, both by experiments and molecular dynamics simulation. Four lubricant additives, viz., CPCa, cyclobutanecarboxylic acid (CBCa), cyclopropane-1,1-dicarboxylic acid (CPDCa), and cyclobutane-1,1-dicarboxylic acid (CBDCa) consisting of a metastable ring structure and one or two carboxyl groups dissolved in an ester base oil were studied. Friction and wear rate using these additives rank in the order of CPDCa

Mechanochemical reactions induced by external stress provide a unique approach for in situ synthesis of carbon tribofilms that can improve friction and wear performance. In this work, we studied how tribofilm formation and tribological performance might be related to the adsorption strength of three additives in polyalphaolefin (PAO4) as base oil, viz., cyclopropanecarboxylic acid (CPCa), cyclopropanemethanol (CPMA), and 1-cyclopropylethanol (CPEA) as characterized by two different surface-active groups –COOH and –OH. Tribo-testing results reveal that addition of 2.5 wt% CPCa to PAO4 gave the lowest friction coefficient and wear volume. FTIR and Raman analysis demonstrate substantial tribofilm formation only in the case when CPCa was used as the oil additive, not CPMA or CPEA, in spite of the fact that all three additives contain the same metastable cyclopropane ring. Thermogravimetric analysis and molecular dynamics simulations indicate the stronger adsorption of CPCa on the iron oxide surface compared with CPMA and CPEA. Weak adsorption of the latter molecules results in their desorption from the surface due to flash heating during tribotesting before they have the chance to participate in mechanochemical reactions required for tribofilm formation. The stronger binding of CPCa to the steel surface is a necessary condition for this type of surface mechanochemistry and appears critical to the efficient formation of carbon-containing tribofilms under our tribo-testing conditions.

Diamond-like carbon (DLC) is a class of amorphous carbon materials used as wear-resistant coatings in tribo-components. The chemical inertness of DLC surfaces, while important in many applications, makes them incompatible with additives in commercial lubricants. Specifically, DLC surfaces do not permit strong adsorption of friction modifier molecules. This study aims at improving the adsorption of these friction modifier molecules on DLC surfaces through an acid treatment. Water contact angle measurements show that such a treatment results in improved hydrophilicity of the DLC. XPS analysis demonstrates 50% increase in the uptake of ArmeenT, an organic friction modifier, on DLC after the acid treatment. This increased ArmeenT adsorption is accompanied by marked decrease in friction in micro-scale friction experiments.

The demand for increased energy efficiency continuously drives the development of new lubricants. Here we report the design and synthesis of hexahydrotriazine, triazine, and cyclen derivatives as friction modifiers (FMs) for enhanced fuel economy. This series of sulfur- and phosphorus-free oil-soluble heterocyclic ring-based molecules exhibits differing thermal and chemical stability depending on the degree of aromatization and number of linking spacers within the central heterocyclic ring. Thermally stable triazine and cyclen FMs significantly increase friction performance in the boundary lubrication regime. Cyclens in particular reduce friction by up to 70% over a wide temperature range. Detailed experimental investigations of the newly synthesized FMs at elevated temperatures demonstrate their favorable tribological performance under four operating conditions: variable-temperature sliding, linear speed ramping, reciprocating sliding, and rolling–sliding contact. These latest experimental findings suggest the potential of the application of “designer” heterocyclic FMs for reducing frictional loss in motor vehicles.

Extreme pressure (EP) lubricant additives form protective tribofilms at the site of contact using the heat and pressure of contact and relative motion. Common EP additives contain undesirable elements such as phosphorus and sulfur. A novel EP lubricant additive, which contains no phosphorus and sulfur, is presented for generating lubricious carbon films. The additive consists of a surface-active molecule with a metastable cycloalkane ring, which dissociates readily during tribological contact to form lubricious carbon films. Friction and wear performance of PAO4 with this additive under a range of loads and speeds were shown to be superior to that without the additive. Optical and scanning electron microscopy and Raman spectroscopy were used to analyze the tribofilms formed on post-test contact surfaces, providing direct evidence for the formation of carbon films. Quantitative kinetics for the carbon tribofilm formation was analyzed as a function of temperature and stress, from which the activation energy for carbon tribofilm formation was obtained.

Modern lubricants face the task of providing lubrication over a wide range of temperatures, and extreme engine temperatures can exceed the thermal degradation limits of many engine oils. Soft metal additives can extend the life of engine oils at very high temperatures by providing solid lubrication to contacting surfaces. We report a new silver–organic complex which contains a high metal content and minimal supporting organic ligands. This silver pyrazole–pyridine complex is evaluated as a friction-reducing and anti-wear additive in engine oil at testing temperatures which thermally degrade the base oil. Two sets of ball-on-disk tests are performed: the first at a constant temperature of 200 °C and the second while increasing the chamber temperature from 180 to 330 °C. At 200 °C, the wear is considerably reduced compared with the base oil when the silver-organic additive is present at 2.5–5.0 wt%. Furthermore, the silver-based additive at 20 wt% in oil induces a remarkable friction reduction during the temperature ramp test, so much, so that the tribological transition from the oil as the primary lubricant to its degradation, and to the silver additive as the primary lubricant, is imperceptible.

Several new siloxane lubricants were synthesized with linear and ring-shaped branch structures of various lengths and branch contents, aiming at a search for better molecular design for lower boundary friction and more effective surface protection against wear of materials. Their molecular structure and mass were measured by means of nuclear magnetic resonance and gel permeation chromatography, respectively. The new lubricants were compared with commercially available polysiloxanes, poly-α-olefins, and perfluoropolyether in lubricating a steel ball-on-steel disk interface using a tribotester at a load of 1.76 GPa and an entrainment speed of 0.025 m/s. The results are used to explain the effects of alkyl branch length L, pendant type J, percent of branch functional monomers Q, and degree of polymerization DP on siloxane design for the most effective boundary lubrication.

This study investigates the rheologic properties, elastohydrodynamic film, and friction coefficients of several siloxane-based lubricants to assess their shear stability and their potential for energy efficient lubrication. Several siloxane-based polymers with alkyl, aryl, and alkyl-aryl branches were synthesized in order to examine the relationship between their molecular structures and tribological performance. Nuclear magnetic resonance spectroscopy and gel permeation chromatography were used to characterize the molecular structures and masses, respectively. Density, viscosity, elastohydrodynamic film thickness, and friction measurements were measured from 303 to 398 K. Film thickness and friction measurements were made at loads and speeds that cover the boundary, mixed, and full film lubrication regimes. These results illustrate that the shear characteristics of siloxane lubricants vary significantly with polymer length as well as branch structure and content. The findings provide quantitative insight into the features of siloxane molecular structure conducive to optimum film formation with minimum wear and elastohydrodynamic friction to enhance energy efficiency.

The molecular structures, rheological properties, and friction coefficients of several new siloxane-based polymers were studied to explore their traction characteristics. The molecular structures including branch content were established by nuclear magnetic resonance spectroscopy, while the molecular mass distributions were determined by gel permeation chromatography. Density, viscosity, elastohydrodynamic film formation, and friction were investigated over a temperature range of 303–398 K. Film thickness and friction measurements were studied under the conditions that are representative of boundary, mixed, and full-film lubrication regimes, aiming at maximizing traction performance and temperature stability by simultaneous optimization of the size and content of ring-shaped branch structures. This study provides quantitative insight into the effect of siloxane molecular structure on the tribological performance for traction drive applications such as continuously variable transmissions.

This article reports an investigation of the effect of melting and microstructure on the microscale friction of several silver–bismuth alloys using a high-temperature nanoindentation-tribotesting system. These studies showed that friction increases with temperature before melting. We modeled these results as due to the softening of the alloys with increasing temperature, which appears to adequately explain the experimental trend. The friction behavior upon melting depends on the alloy composition. For some alloy composition, friction was observed to exhibit a sharp decrease upon melting, while for another alloy composition, friction was observed to keep increasing with temperature. This unusual behavior can be explained by the difference in microstructure and phase composition as a function of temperature among different Ag–Bi alloys.

The attempt of a recent paper to relate grease degradation with entropy generation is analysed. The analysis shows the deficiency of such an approach.

Boron carbide (B4C) is well known for its high hardness and favorable wear resistant properties. In dry sliding wear contact, it polishes its mating surface and provides fatigue resistance to coated parts. Employing such run-in coatings demands a thorough understanding of the parameters which directly influence the changes that occur in the coating abrasiveness during the polishing process. In this study, the effects of the overall coating thickness, overall coating roughness, substrate roughness and substrate roughness orientation are examined in connection with abrasiveness. The coating thickness only influences the initial abrasiveness, whereas the coating roughness drastically affects the rate at which the abrasiveness decreases. Finally, no significant changes are observed in the abrasiveness due to substrate roughness or substrate roughness orientation effects. This work provides further insight into the design of a finite-life run-in coating.

This paper reports the effects of thermal softening on asperity contacts. We modified the thermomechanical asperity model previously developed by Liu and Wang based on discrete convolution, fast Fourier transform and the conjugate gradient method and applied it to the current study. The yield strength was assumed to be a function of local asperity temperature. Asperity contact pressure and contact area with and without such temperature effects were analyzed and compared.

Titanium diboride has many interesting physical and chemical properties that make it attractive as a tribological coating material. We focus our study on the relationship between hardness, crystal structure and processing parameters for TiB2 thin films produced by conventional and ionized magnetron sputtering. When synthesized by conventional magnetron sputtering, TiB2 films with the highest degree of crystallinity have the highest hardness and are obtainable at an optimum combination of argon pressure and substrate bias. The films also show strong (0001) texture. Such high degree of crystallinity can be obtained without substrate bias by ionized magnetron sputtering, in which enhanced ionization of the plasma is obtained by inductively coupling RF power in the region between the magnetron target and the substrate.

Two common tribo-failure mechanisms are discussed in this paper.The first mechanism deals with the role of asperity flashtemperature in scuffing (severe adhesive wear) failure. Thesecond mechanism is concerned with the generation andaccumulation of wear particles in the contact zone in initiatingtribo-failure. These failure mechanisms can be suppressed bycontrolling the surface geometry, incorporating the properlubricant package and surface modification.

Nanoindentation hardness and compressive stress in amorphous carbon nitride thin films prepared by unbalanced magnetron sputter-deposition were studied. The coating hardness and compressive stress were found to be strongly dependent on processing parameters such as substrate bias and nitrogen partial pressure. Under optimized deposition conditions, carbon nitride thin films with nanoindentation hardness about 25 GPa have been coated onto Si wafers and M2 steels. A strong correlation between coating hardness and compressive stress in the coating was observed.

This study investigates the rheological properties, elastohydrodynamic film thickness, and friction coefficients of several commercially available polyalphaolefin (PAO) and polydimethylsiloxane (PDMS)-based lubricants to assess relationships between molecular structure and lubricant performance. Molecular structures and masses were determined by nuclear magnetic resonance spectroscopy and gel permeation chromatography, respectively. Density and viscosity are measured from 303 to 398 K, while elastohydrodynamic lubricant film thickness and friction measurements were made at temperatures, loads, and speeds that are representative of boundary, mixed, and full-film lubrication regimes. The results show that PDMS-based lubricants are thermally and oxidatively more stable than PAOs, while the viscosity of PDMS-based lubricants is generally less temperature sensitive than PAOs, except for highly branched polysiloxanes. In particular, this study provides quantitative insight into the use of PDMS-based lubricants to obtain low friction through the entire lubrication regime (boundary to full film) by optimal tuning of the molecular mass and chain branching.