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Coatings for wear and lubrication

In this paper we review the recent advances in the tribological uses of R.F.-sputtered and ion-plated films of solid film lubricants (laminar solids, soft metals, organic polymers) and wear-resistant refractory compounds (carbides, nitrides, silicides). The sputtering and ion-plating potentials and the corresponding coatings formed are evaluated relative to the friction coefficient, wear endurance life and mechanical properties. The tribological and mechanical properties of each kind of film are discussed in terms of film adherence, coherence, density, grain size, morphology, internal stresses and thickness and substrate conditions such as temperature, topography, chemistry and d.c. biasing. The ion-plated metallic films in addition to improved tribological properties also have better mechanical properties such as tensile strength and fatigue life.

Spalvins, T.↗

Low-Reynolds-number turbulent boundary layers

A test facility operating at substantially reduced pressures is described and shown to be suitable when used with an open-circuit turbulent boundary layer wind tunnel. The facility is capable of producing flows with momentum Reynolds number in the range 200-10,000 by varying the ambient pressure. At low-Reynolds-number flows the pressure is low enough to allow the tunnel to operate with large values of freestream speed. The tunnel's reliability is verified by examining flows where momentum Reynolds number is greater than 1200. The results skin friction coefficients, wake parameters, and basic velocity profiles - consistently agreed with well-established data. For momentum Reynolds number from 600 through 1200 the resulting data indicate that the 'universal velocity profile' is accurate and correctly describes the mean flow properties. For Reynolds number from 425 through 600, the viscous sublayer in this range can no longer maintain its characteristic size.

White, B. R.↗

Friction and wear of plasma-sprayed coatings containing cobalt alloys from 25 deg to 650 deg in air

Four different compositions of self-lubricating, plasma-sprayed, composite coatings with calcium fluoride dispersed throughout cobalt alloy-silver matrices were evaluated on a friction and wear apparatus. In addition, coatings of the cobalt alloys alone and one coating with a nickel alloy-silver matrix were evaluated for comparison. The wear specimens consisted of two, diametrically opposed, flat rub shoes sliding on the coated, cylindrical surface of a rotating disk. Two of the cobalt composite coatings gave a friction coefficient of about 0.25 and low wear at room temperature, 400 and 650 C. Wear rates were lower than those of the cobalt alloys alone or the nickel alloy composite coating. However, oxidation limited the maximum useful temperature of the cobalt composite coating to about 650 C compared to about 900 C for the nickel composite coating.

Sliney, H. E.↗

Comparison of the tribological properties at 25 C of seven different polyimide films bonded to 301 stainless steel

A pin-on-disk type of friction and wear apparatus was used to study the tribological properties of seven different polyimide films bonded to AISI 301 stainless steel disks at 25 C. It was found that the substrate material was extremely influential in determining the lubricating ability of the polyimide films. All seven films spalled in less than 1000 cycles of sliding. This was believed to be caused by poor adherence to the 301 stainless steel or the inability of the films to withstand the high localized tensile stresses imparted by the deformation of the soft substrate under sliding conditions. The friction coefficients obtained for six of the polyimides varied between 0.21 to 0.32 while one varied between 0.32 to 0.39.

Fusaro, R. L.↗

Simulation of flat-plate turbulent boundary layers in cryogenic tunnels

The magnitudes of real-gas effects on flat-plate turbulent boundary layer simulations in a cryogenic nitrogen wind tunnel are investigated in order to determine the validity of the method used by Inger (1979) to estimate real-gas effects. Boundary layer solutions for real gases, ideal gases with a specific heat ratio of 1.6 and ideal diatomic gases (specific heat ratio 1.4) were obtained for the worst case conditions of maximum stagnation pressure (9 atm), minimum stagnation temperature (120 K) and Mach number of 1.2. Calculated boundary layer parameters such as friction coefficient and displacement thickness are shown to agree closely for the real gas and the ideal diatomic gas (specific heat ratio 1.4), while the ideal gas solution used by Inger is shown to differ from the real-gas values considerably. Results indicate that real-gas effects on a flat-plate turbulent boundary layer simulation in a cryogenic nitrogen tunnel are insignificant, and suggest the unlikelihood of the large real-gas effects reported by Inger for turbulent boundary layer shock interactions.

Adcock, J.↗

Friction and wear of plasma-sprayed coatings containing cobalt alloys from 25 deg to 650 deg in air

Four different compositions of self-lubricating, plasma-sprayed, composite coatings with calcium fluoride dispersed throughout cobalt alloy-silver matrices were evaluated on a friction and wear apparatus. In addition, coatings of the cobalt alloys alone and of one coating with a nickel alloy-silver matrix were evaluated for comparison. The wear specimens consisted of two, diametrically opposed, flat rub shoes sliding on the coated, cylindrical surface of a rotating disk. Two of the cobalt composite coatings gave a friction coefficient of about 0.25 and low wear at room temperature, 400 and 650 C. Wear rates were lower than those of the cobalt alloys alone or the nickel alloy composite coating. However, oxidation limited the maximum useful temperature of the cobalt composite coating to about 650 C compared to about 900 C for the nickel composite coating.

Sliney, H. E.↗

The subtidal response of sea level to atmospheric forcing in the Carolina Capes

The subtidal frequency response of sea level to atmospheric forcing along the coastal region between Cape Hatteras and Charleston is investigated for a four-month period: 1 September-31 December, 1974. It is found that low-frequency sea level fluctuations are preferentially forced by wind stress components which are aligned with the local topography. Also, a localized, one-dimensional model of sea surface response to a clockwise rotating wind for the Charleston coastal regime is developed. The phase spectrum of the alongshore wind component versus sea level as predicted by the model is shown to compare favorably to that derived from actual observations at Charleston, an open ocean coastal site. The model results and observations also suggest that wind-induced fluctuations of coastal sea level are trapped within 40 km of the coast by the combined effects of friction, Coriolis force and bottom topography. The outer shelf is dominated by fluctuations which are less related to wind stress and are attenuated rapidly in the shoreward direction. A reasonable estimate of bottom frictional coefficient, r = 0.05 cm/s, is also established.

Chao, S.-Y.↗

Effect of load, area of contact, and contact stress on the wear mechanisms of a bonded solid lubricant film

A pin on disk type of friction and wear apparatus was used to study the effect of load, contact stress and rider area of contact on the friction and wear properties of polyimide bonded graphite fluoride films. Different rider area contacts were obtained by initially generating flats (with areas of 0.0035, 0.0071, 0.0145, and 0.0240 cm) on 0.476-cm radius hemispherically tipped riders. Different projected contact stresses were obtained by applying loads of 2.5- to 58.8-N to the flats. Two film wear mechanisms were observed. The first was found to be a linear function of contact stress and was independent of rider area of contact. The second was found to increase exponentially as the stress increased. The second also appeared to be a function of rider contact area. Wear equations for each mechanism were empirically derived from the experimental data. In general, friction coefficients increased with increasing rider contact area and with sliding duration. This was related to the build up of thick rider transfer films.

Fusaro, R. L.↗

A new coordinate transformation for turbulent boundary layer flows

The transformation permits a uniform mesh to be used in the computational coordinate which extends across the layer. This coordinate transformation uses the local value of the skin friction coefficient to scale the thickness of the wall layer region, and the local maximum value of turbulent viscosity to scale the boundary-layer thickness. Results are presented for two dimensional boundary layers in both positive and negative pressure gradients and comparisons are made with experimental data and conventional variable-grid results for low speed turbulent boundary-layers. The cases chosen illustrate the capability of this new transformation to capture the boundary layer growth over the full extent of laminar, transitional, and turbulent flow with no grid adjustment as well as its ability to consistently enlarge the wall layer region for accurate shear stress representation. Results of mesh refinement studies using the new coordinate transformation are presented.

Carter, J. E.↗

Evaluation of boundary lubricants using steady-state wear and friction

A friction and wear study was made at 20 C to establish operating limits and procedures for obtaining improved reproducibility and reliability in boundary lubrication testing. Ester base and C-other base fluids were used to lubricate a pure iron rider in sliding contact with a rotating M-50 steel disk in a pin-on-disk apparatus. Results of a parametric study with varying loads and speeds slowed that satisfactory test conditions for studying the direction and wear characteristics in the boundary lubrication regime with this test device were found to be 1 kilogram load; 7 to 9 meters-per-minute (50 rpm) surface speed; dry air test atmosphere (less than 100 ppm H2O); and use of a time stepwise procedure for measuring wear. Highly reproducible steady-state wear rates resulted from the two fluid studies which had a linearity of about 99 percent after initially higher wear rates and friction coefficients during run-in periods of 20 to 40 minutes.

Loomis, W. R.↗

Review of antiskid and brake dynamics research

The behavior of various antiskid systems was investigated under controlled conditions. Results from utilizing a single main wheel of a DC-9 aircraft suggest that the systems investigated perform well under most circumstances but there may be room for improvement. For example, it was demonstrated that pressure bias modulation can adversely affect the response of antiskid systems to rapid changes in the runway friction level. Results also indicate that antiskid systems designed to operate at a slip ratio of approximately 0.1 can provide a maximum braking effort without undue loss in the cornering capability of the tire. Time histories of braking friction coefficient were shown to provide a means of determining antiskid system performance and for systems that employed pressure bias modulation it was shown that performance could also be estimated from time histories of brake pressure and torque.

Stubbs, S. M.↗

Studies of some unconventional systems for solving various landing problems

Solutions to various landing problems were obtained through unconventional systems. The first, of these is the air cushion landing system, where efforts were concentrated on development of adequate braking and steering systems and an improved understanding of scaling laws and behavior. The second was concentrated on use of a wire brush skid as a drag producing device, which was shown to have good friction coefficients and reasonable wear rates at ground bearing pressures up to 689 kPa and forward speeds up to 80 km/hr. The third showed great promise in an active control landing gear where significant load reductions were possible during landing impact and subsequent rollout.

Leland, T. J.↗

Steady-state boundary lubrication with formulated C-ethers to 260 C

Steady state wear and friction studies were made at boundary lubrication conditions in a pin on disk (pure iron on rotating CVM M 50 steel) sliding friction apparatus with five C ether formulated fluids (modified polyphenyl ether containing phosphrous ester, organic acid, and other additives). Conditions included 20, 150, and 260 C disk temperatures, dry air test atmosphere, 1 kilogram load, 50 rpm disk speed, and test times to 130 minutes. Results were compared with those obtained with a formulated MIL L 27502 candidate ester and the C ether base fluid. Three of the C ether formulations gave better lubrication than both reference fluids under most conditions. The other two C ether formulations yielded higher wear rates and friction coefficients than the C ether base fluid for most of the temperature range. Only one C ether formulation showed consistently higher steady state wear rates than the ester.

Loomis, W. R.↗

Behavior of aircraft antiskid braking systems on dry and wet runway surfaces: Hydromechanically controlled system

The investigation utilized one main gear wheel, brake, and tire assembly of a McDonnell Douglas DC-9 series 10 airplane. The landing-gear strut was replaced by a dynamometer. During maximum braking, average braking behavior indexes based upon brake pressure, brake torque, and drag-force friction coefficient developed by the antiskid system were generally higher on dry surfaces than on wet surfaces. The three braking behavior indexes gave similar results but should not be used interchangeably as a measure of the braking of this antiskid sytem. During the transition from a dry to a flooded surface under heavy braking, the wheel entered into a deep skid but the antiskid system reacted quickly by reducing brake pressure and performed normally during the remainder of the run on the flooded surface. The brake-pressure recovery following transition from a flooded to a dry surface was shown to be a function of the antiskid modulating orifice.

Tanner, J. A.↗

Modification in drag of turbulent boundary layers resulting from manipulation of large-scale structures

The effects of placing a parallel-plate turbulence manipulator in a boundary layer are investigated by means of flow visualization and hot-wire measurements. The manipulator was found to be effective in inhibiting the intermittent large scale structure of the boundary layer, and the effect persists for at least 70 boundary-layer thicknesses downstream of the manipulator. With the removal of the large scale, there was an observed reduction in the streamwise turbulence intensity levels near the wall. The downstream distribution of the skin friction coefficient, determined from the stream wise change in fluid momentum, was also altered by the introduction of the manipulator. The data from both the visualization and hot wire studies are provided.

Corke, T. C.↗

Experimental investigation of drag on a compliant surface

The feasibility of reducing turbulent skin-friction drag by means of surface compliance was studied experimentally in a fully developed flat-plate turbulent boundary layer in air, using a membranous surface backed by a thin cavity containing a layer of polyurethane foam. Surface motion characteristics, boundary layer structure, and overall drag were measured over a range of freestream speeds from 7 to 30 m/sec, and a range of membrane tensions from 44 to 350 N/m. Low-amplitude long-wavelength motions predominate, and no significant change from the rigid surface skin-friction coefficients was observed.

Mcmichael, J. M.↗

Tribological characteristics of nitrogen (N+) implanted iron

The effect of implantation of nitrogen ions (1.5 MeV) on the friction and wear characteristics of pure ion sliding against M-50 steel (unimplanted) was studied in a pin-on-disk sliding friction apparatus. Test conditions included room temperature (25 C), a dry air atmosphere, a load of 1/2 kg (4.9 N), sliding velocities of 0.043 to 0.078 m/sec (15 to 25 rpm), a pure hydrocarbon lubricant (n-hexadecane), or a U.S.P. mineral oil and nitrogen ion implantation doses of 5x10 to the 15th power and 5x10 to the 17th power ions/sq cm. No differences in wear rates were observed in the low dose experiments. In the high dose experiments, small reductions in initial (40 percent) and steady state (20 percent) wear rates were observed for nitrogen implanted iron riders as compared with unimplanted controls. No differences in average friction coefficients were noted for either dose. Auger electron spectroscopy combined with argon ion bombardment revealed a subsurface Gaussian nitrogen distribution with a maximum concentration of 6 atomic percent at a depth of 0.8 microns. Similar analysis within the wear scar of an implanted rider after 20 microns of wear yielded only background nitrogen concentration. No inward migration of nitrogen ions was observed.

Jones, W. R.↗

A vectorized code for calculating laminar and turbulent hypersonic flows about blunt axisymmetric bodies at zero and small angles of attack

A user's guide is provided for a computer code which calculates the laminar and turbulent hypersonic flows about blunt axisymmetric bodies, such as spherically blunted cones, hyperboloids, etc., at zero and small angles of attack. The code is written in STAR FORTRAN language for the CDC-STAR-100 computer. Time-dependent, viscous-shock-layer-type equations are used to describe the flow field. These equations are solved by an explicit, two-step, time asymptotic, finite-difference method. For the turbulent flow, a two-layer, eddy-viscosity model is used. The code provides complete flow-field properties including shock location, surface pressure distribution, surface heating rates, and skin-friction coefficients. This report contains descriptions of the input and output, the listing of the program, and a sample flow-field solution.

Kumar, A.↗