C532-PP-M14-01-02

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EUROPEAN CONCERTED ACTION ON

“Triboscience and Tribotechnology: Superior friction and wear control in engines and transmissions”

COST 532 Project proposal

1. INFORMATION (SUMMARY) SHEET FOR A PROPOSAL

1.1 Title of project

Rolling and rolling-to-sliding contact failure mechanisms of diamond like coatings

Co-ordinator (full name and address) Dr. Mitjan Kalin University of Ljubljana Faculty of mechanical engineering Centre for Tribology and Technical Diagnostics Bogišiceva 8 SI-1000 Ljubljana SLOVENIA

August, 2002

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1.2 Information on participating members

1.2.1 Participant 1

1.2.1.1 Center for tribology and technical diagnostics Full address (including specific laboratory where studies will be undertaken, if relevant to address)

University of Ljubljana, Faculty of Mechanical Engineering Centre for Tribology and Technical Diagnostics Bogišiceva 8 SI-1000 Ljubljana SLOVENIA

Tel.: +386 1 4771-460 Fax: +386 1 4771-469

1.2.1.2 Scientist responsible for the project (if different from the applicant)

Dr. Mitjan Kalin, Assistant professor University of Ljubljana Centre for Tribology and Technical Diagnostics Bogišiceva 8 SI-1000 Ljubljana SLOVENIA

Tel.: +386 1 4771-462 Fax: +386 1 4771-469 E-mail: [email protected] lj.si

1.2.1.3 Proposed effort in man/years per annum of graduates, scientists and technicians. • 0.3 man per year – scientists (total 1 Man-years) • 0.5 man per year – Ph.D. students (total 1.5 Man-years) • 0.5 men per year – technicians (total 1.5 Man-years)

1.2.1.4 Total cost of project, including: amount requested (or already

awarded) from National resources; funding required for project per annum; total required for duration of the project.

Costs in kEuro

Center for Tribology and Technical diagnostics, University of Ljubljana

2003 2004 2005 Total

Mantime 23 23 23 69

Instrument time,

Consumables 11 11 11 33

Travels 3 3 3 9

Total 37 37 37 111

The total cost for the participation of Center for tribology and technical diagnostics in the proposed project is 111 kEuro. The cost for Instrument time, consumables and travels, i.e. 42 kEuro, is asked for from the Slovenia national resources.

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1.2.2 Participant 2

1.2.2.1 Volvo Technology Corporation Full address (including specific laboratory where studies will be undertaken, if relevant to address)

Volvo Technology Corporation Department of Surface Engineering Chalmers Teknikpark SE-412 88 Göteborg Sweden

Tel.: +46 31 7724090 Fax: +46 31 820887


Per H Nilsson, Manager Volvo Technology Corporation Dept. 06520, CTP SE-412 88 Göteborg Sweden

Tel.: +46 31 7724090 Fax: +46 31 820887 E-mail: [email protected]

1.2.2.3 Proposed effort in man/years per annum of graduates, scientists and technicians.

• 0.3 man per year – scientists (total 0.9 Man-years)

1.2.2.4 Total cost of project, including: amount requested (or already awarded) from National resources; funding required for project per annum; total required for duration of the project.

Costs in kEuro

Volvo Technolgy, VTEC 2003 2004 2005 Total

Mantime 30 30 30 90

Instrument time 5 5 5 15


Travels 5 5 5 15

Total 45 45 45 135

The total cost for the participation of Volvo Technology in the proposed project is 135 kEuro. The cost for travels, 15 kEuro, is asked for from the Swedish authorities.

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1.2.3 Participant 3

1.2.3.1 Volvo Car Corporation Full address (including specific laboratory where studies will be undertaken, if relevant to address)

Volvo Car Corporation Transmission Development

Department 97712, HABVS SE-405 31 Göteborg Sweden

Tel.: +46 31 3257930 Fax: +46 31 593649


Dr. Naser Amini, Manager Volvo Car Corporation Dept. 97712, HABVS SE-405 31 Göteborg Sweden

Tel.: +46 31 3257030 Fax: +46 31 593649 E-mail: [email protected]


• 0.3 man per year – scientists (total 0.9 Man-years) 1.2.3.4 Total cost of project, including: amount requested (or already

awarded) from National resources; funding required for project per annum; total required for duration of the project.

Costs in kEuro

Volvo Cars 2003 2004 2005 Total

Mantime 30 30 30 90

Mantime, VTEC

10 10 10 30

Rig time 0 5 15 20


Travels 5 5 5 15

Total 50 55 65 170

Volvo Cars will finance the total cost for Volvo Cars participation in the proposed project.

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1.2.4 Participant 4

1.2.4.1 Halmstad University, School of Business and Engineering Full address (including specific laboratory where studies will be

undertaken, if relevant to address) Halmstad University School of Business and Engineering PO Box 823 301 18 Halmstad Tel.: +46 35 16 71 00

Fax: +46 35 16 75 00


Prof. Bengt-Göran Rosén, PhD Halmstad University Functional Surfaces Research Group School of Business and Engineering PO Box 823, Halmstad SWEDEN

Tel.: +46 35 16 76 04 Fax: +46 35 16 75 00 E-mail: [email protected]


• 0.2 man per year – scientists • 0,5 man per year – Ph.D. students

1.2.4.4 Total cost of project, including: amount requested (or already awarded) from National resources; funding required for project per annum; total required for duration of the project.

20.000 Euro per year (seniors, already granted, requested) 32 000 Euro per year (PhD student, rig and material, requested)

Costs in kEuro Halmstad University 2003 2004 2005 Total

Mantime, senior 20 22 24 66

Mantime, PhD stud 22 24 26 72

Rig time 5 5 10 20


Travels 8 8 8 24

Total 60 64 73 197 The total cost for the participation of Halmstad University in the proposed project is 197 kEuro. The cost for travels, 24 kEuro, is asked for from the Swedish authorities.

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1.3 Probable duration of project.

3 years 1.4 Date at which it is desired that work should begin. 01.01.2003 1.5 International cooperation with other Signatory States of the

Memorandum of Understanding Proposed sub-contractors (discussion in progress) 1. VITO (Ir. Jan Meneve), Mol, Belgium 2. SKF COATED BEARINGS (Dr. Victoria Wikstrom), Gothenburg, Sweden 3. SVUM Inc. (Dr. Jan Suchánek), Prague, Czech Republic

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2. ABSTRACT In the last decade a tremendous research work has been done in the field of development and characterization of hard coatings, mainly to boost their use in machine component applications working under normal and extreme operating conditions. Until now, hard coatings have been extensively investigated only for pure sliding applications, while the rolling contact mechanisms are rarely reported and there is a tremendous lack of knowledge in this area. On the other hand, hard-coated rolling bearings and gears are already in use, but because of the above reasons their applicability is still very limited. However, a great potential for their significantly increased use is due to the fact that conventional rolling bearings and gears are amongst most used machine elements in nowadays machinery. Accordingly, demands for better understanding of the rolling and rolling-to-sliding contact failure mechanisms in hard-coated systems, seem to be justified. The aim of the proposed project is therefore to investigate the rolling and rolling- to-sliding contact mechanisms and failure modes of different diamond like carbon coatings (DLC) deposited on bearing- and gear steel substrates. Special attention will be considered to investigate the influence on surface roughness and lay direction influence on the mechanisms studied. The surface and subsurface analyses will be used to locate and detect failure modes. In addition, complementary techniques, operational parameters and subsequent mathematical modeling should allow us to better understand the failure mechanisms, initiation and growth of cracks, the role of shear stresses, coatings adhesion, and other critical rolling wear and fatigue parameters. Contact mechanisms will be investigated under dry as well as lubricated conditions using a specifically designed in-house rolling and rolling-to-sliding contact test rigs. Results of this investigation should give more detailed insight into the rolling and combined rolling/sliding contact mechanisms of hard coatings, and simplify a coating selection process for the specific machine component application. Finally, results will be followed-up and verified in industrial try-outs at the partners sites.

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3. PROJECT PROPOSAL INFORMATIONS

3.1 Aim of the study

The proposed project will focus on failure mechanisms of DLC-coated bearing steel under dry and lubricated rolling and rolling-to-sliding contact conditions, which apply for rolling bearings and gears, respectively. Rolling bearings and gears are one of the most commonly used machine components and the demands for their improved performance and use in severe and new applications are increasing constantly. Hard coatings, especially diamond like coatings (DLC) are promising materials to help achieving these goals: for example operation under poor lubrication conditions, the need for increased transmitted power in gears, or lowering friction and energy consumption, but also for other purposes. Moreover, bearings and gears with coated raceways and gear flanks are already used and investigated, but the amount of knowledge on possible failure mechanisms, and thus the reliability of DLC-hybrid bearings and gears still limit their broader use. However, the huge amount of conventional bearings and gears in all kinds of machines and devices is a tremendous potential and challenge for use of such high-tech machine elements in many applications, amongst which, also transmissions and engines. This can, however, only be achieved by better knowledge and models of the rolling and combined rolling and sliding contact failure mechanisms, and consequently improved reliability of bearings and gears. Despite the huge amount of studies and work on DLC coatings in last decade, these were performed mainly in the pure sliding conditions, while the rolling contact conditions were over-disregarded. One of the reasons for the lack of these investigations is also difficulty for preparing rolling contact samples, which bring many technical problems, and are usually very expensive. However, our new in-home rolling contact device, which was recently patented, allows rather simple testing procedures at reasonable price, with much simpler samples than used in conventional devices, and this can help us in performing a comprehensive study of DLC coatings with various parameters and conditions used. So, the proposed study will bring new knowledge and understanding of the rolling contact failure mechanisms for different DLC coatings that is necessary to achieve above mentioned goals. The specially designed rolling-to-sliding test rig at Halmstad University will in addition to the patented test-rig enable possibilities to study the influence of lay direction and substrate roughness on the coating performance. Moreover, the lab-scale results and conditions will be investigated and verified by industrial partners using the full-scale rolling bearings and gears test rigs.

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3.2 Background to the study

Hard wear resistant coatings are already successfully used in computer, microelectronic, aviation, automobile, textile, biomedical, optical and other industries. Nowadays, the highest emphasis is on the research and development of multilayers, diamond and diamond like carbon coatings (DLC) [1-6]. Multilayer technology gives a great number of possibilities to simultaneously improve different properties of the contact surfaces, i.e. hardness, toughness, tribological properties etc. [7-9]. DLC coatings possess high hardness, good elastic properties; high wear resistance and, very important for machine components, low friction against many different materials [10-12]. DLC coatings can also be deposited at relatively low deposition temperatures (< 200°C), which is important for maintaining properties of substrates at required values. Beside these properties, which rank DLC coatings as very suitable candidates for machine component applications, they are also inert and possess low surface energy [10]. In a huge number of investigations, multilayer ceramic coatings and DLC coatings showed excellent wear and friction behavior under various sliding conditions [6, 12-17]. However, many of machine components, like rolling bearings, gears and camshafts , are exposed to pure rolling or combination of sliding and rolling. Therefore, the acting wear and fatigue mechanisms are different [18,19]: the rolling wear and rolling fatigue will become predominant. Rolling failures may start in the subsurface region or at the surface [20,21]. In the first case, initiation and propagation of fatigue cracks are determined by shear stresses (friction dependent), but in the case of coated materials, other phenomena will also play a role, like coating adhesion and combined coating-to-substrate mechanical properties. On the other hand, rolling failure which originates at the surface (wear and micropitting) depends mostly on the surface roughness, irregularities [22] and type of lubrication. When sliding is added to the rolling, the failure mechanisms become more complex and to certain extent a combination of the two modes. Initiation and propagation of surface failure can be avoided or postponed by use of better surface finish [21]. However, this is not always technologically achievable or economically defendable. One possible solution is to use hard coating technology [23]. Physically vapor deposited TiN coating is successfully used in the case of cutting tools. However, in the case of rolling contact the results were very different [24-29]. Sometimes the coatings performed rather poorly [24-26], but with some modifications of deposition parameters and especially coating thickness much better results were achieved [27-29]. Similar behavior was observed for majority of hard ceramic coatings [30]. DLC coatings with a high surface hardness and low friction seem to be very promising and suitable solution for improving rolling contact behavior, however, seldom investigations with these coatings still report the contradictory results [23,31,32]. In addition, the tribological behavior of DLC (and other) coatings is greatly influenced by coating deposition parameters, coating thickness and also operational and environmental conditions, which makes them even more difficult to compare. It is obvious that much more comprehensive set of DLC coatings with various parameters and testing conditions used need to be investigated for providing better answers and understanding of failure modes. One of the limiting factors for broad and comprehensive studies of different parameters influencing rolling- and rolling- to-sliding contact behavior is also the cost

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of manufacturing and deposition for the preparing samples and the complexity of the testing procedures. Most of the testers in current use for rolling- and rolling- to-sliding contact fatigue and wear, for example, disc-on-disc, ball-on-rod and the modified four-ball machine use relatively large and expensive samples, especially in the case when high-tech materials are used. In addition, these conventional machines are designed in such a way that the specimen or counter material revolves on an axis, typically at high speed, to reduce the testing time. The very complex geometry of the specimens, and the machine, is therefore unavoidable and very fine tolerances are demanded. In addition, careful and time-consuming mounting and dismounting procedures are necessary. This makes these kind of experiments relatively expensive and time-consuming. Moreover, with some deposition techniques and devices, full circumferential and uniform specimen properties cannot be obtained. Therefore, the use of our in-house made and patented device [33,34] that uses the ball-on-flat testing principle gives us possibility of performing a comprehensive study with simple flat samples (instead of conventional complex circular-shaped specimens), that allow variation of almost any parameter (deposition and operational), and very importantly, due to simple geometry and size, with uniform and known properties [35,36]. Understanding of rolling contact mechanisms and developing appropriate models are crucial for the optimization and successful use of DLC coatings in the field of machine components. The results of the proposed study can provide the mechanisms and conditions, under which, better performance of DLC coated components can be obtained and thus increased use of these high- tech machine elements can be expected for better efficiency and reliability in various demanding fields of operation, like transmissions and engines. The recently developed test-rig at Halmstad University will here further increase the possibilities to connect roughness and lay directions influence on the components performance and the mechanisms studied. REFERENCES [1] T. Bell; Engineering the Surface to Combat Wear; Thin Films in Tribology, Elsevier,

1993, 27-37 [2] D.S.Rickerby, A. Matthews; Advanced surface coatings, A handbook of surface

engineering, Glasgow, 1991 [3] T. Bell; Towards Designer Surfaces, Industrial Lubrication and Tribology, Vol. 44,

No.2,1992, 3-11 [4] K. Holmberg, A. Matthews; Coating Tribology: Properties Techniques and Applications

in Surface Engineering, Tribology series 28, Elsevier, 1994 [5] C. Schurer, U.Semmler, Advanced applications of diamond-like carbon coatings, Surface

Engineeing, EUROMAT ?99, Vol.1, 2000, 235-240 [6] A. Skopp, D. Klaffke; Friction and wear behaviour of hard coatings in vibrating contacts;

Tribotest, Vol.6. 1999, 171-192 [7] O. Knotek, F. Löffner and G. Krämer; Multicomponent and multilayer PVD Coatings for

Cutting Tools, Surface and Coatings Technology, Vol. 54/55, 1992, 241-248 [8] Z.Renji; I. Ziwei and C. Zhouping; Studies on Multilayer Wear of CVD TiC-TiN

Multilayer Composites Coatings, Wear, Vol.147,1991,227-251 [9] C. Subramanian, K.N. Strafford; Review of Multicomponent and Multilayer Coatings for

Tribological Applications, Wear, Vol. 163, 1993, 85-95. [10] A. Grill; Tribology of diamendlike carbon and related materials: an update review,

Surface and Coating Technology, Vol. 94-95, 1997,507-513 [11] P. Kodali, K.C. Walter, M.Nastasi; Investigation of mechanical and tribological

properties of amorphous diamond-like carbon coatings, Tribology International, Vol. 30.1997, 591-598

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[12] A. Erdemir et all.;Friction and wear mechanisms of smooth diamond films during sliding in air and dry nitrogen, ASME Tribology Transactions, Vol. 40. 1997, 667-675[

13] S.J.Bull, P.R.Chalker; Lubricated sliding wear of physical vapour deposited titanium nitride, Surface and Coating Technology, Vol. 50, 1992, 117-126

[14] H. Ronkainen, S. Varjus, K. Holmberg; Friction and wear properties in dry, water-and oil-lubricated DLC against alumina and DLC against steel contacts, Wear, Vol. 222, 1998, 120-128

[15] C. Donnet, A. Grill; Friction control of diamond-like carbon coating, Surface and Coatings Technology, Vol. 94-95, 1997, 456-462

[16] Y. Liu, A.Erdemir, E.I. Meletis; Influence of environmental parameters on the frictional behavior of DLC coating, Surface and Coatings Technology, Vol. 94-95, 1997,463-468

[17] C. Donnet et all.; Tribochemistry of diamond-like carbon coatings in various environments, Surface and Coatings Technology, Vol. 68/69, 1994, 626-631

[18] T.A. Stolarski; Tribology in Machine Design, Butterworth Heinemann, 2000 [19] G.W. Stachowiak, A.W. Batchelor; Engineering Tibology, Elsevier, 1993 [20] G.R. Miller, L.M. Keer, H.S. Cheng; On the mechanics of the fatigue crack growth due

to contact loading, Proc. Roy. Soc. London; Vol. A 397, 1985, 197-209 [21] T.A. Harris; Rolling Bearing Analysis, Wiley, 1991 [22] P. Sainsot, J.M. Leroy, B. Villechaise; Effect of surface coatings in a rough normally

loaded contactc, Mechanics of coatings, Elsevier, 1990 [23] A. Erdemir; Rolling-contact fatigue life and wear resistance of hard coatings on bearing-

steel substrates; Surface and Coatings Technology, Vol. 54/55, 1992, 482-489 [24] J.F. Dill, M.N. Gardos, H.E. Hintermann, H.J. Boving; Rolling contact fatigue evaluation

of hardcoated bearing steels, Proceedings 3rd Int. Conf. on Solid Lubrication, Denver, 1985, 230-241

[25] A. Erdemir; A study of surface metallurgical characteristics of TiN-coated bearing steels, Ph.D. Thesis, Georgia Institute of Technlogy, Atlanta, 1986.

[26] T.P. Cheng, H.S. Cheng, W.D. Sproul; The influence of coating thickness on lubricated rolling-contact fatigue life, Surface and Coatings Technology, Vol. 43-44, 1990, 699-708

[27] R.M. Middleton, P.J. Huang, M.G.H. Wells, R.A. Kant; Effect of coatings on rolling contact fatigue behaviour of M50 bearing steel, Surface Engineering, Vol. 7, 1991, 319-326

[28] T.P. Chang; Tribological behaviour of titanium nitride-coated rollers, Ph.D. Thesis, Northwestern University, Evanston, 1991

[29] T.P. Chang, H.S. Cheng, W.A. Chiou, W.D. Sproul; A comparison of fatigue failure morphology between TiN-coated and uncoated lubricated rollers, Tribology Transactions, Vol. 34, 1991, 408-416

[30] R. Thom, L. Moore, W.D. Sproul, T.P. Chang; Rolling contact fatigue tests of reactivity sputtered nitride coatings of Ti, Zr, Hf, Cr, Mo, TiAl, TiZr and TiAlV on 440C stainless steel, Surface and Coatings Technology, Vol. 62, 1993, 423-427

[31] L. Rosado, V.K. Jain, H.K. Trivedi; The effect of diamond-like carbon coatings on the rolling fatigue and wear of M50 steel, Wear, Vol. 212, 1997, 1-6

[32] B. Podgornik, J. Vižintin; Rolling contact properties of ta-C coated low alloy steel; Surface and Coatings Technology, Vol. 157, 2002, 257-261

[33] M. Kalin, J. Vizintin, “Apparatus for testing rolling contact fatigue resistance of materials with possible interruptions,” Docket No. P-5978.6/G-5978; Washington, D.C. 20231: Commissioner of Patents and Trademarks, Approved (2002).

[34] J. Vizintin, M. Kalin, “Apparatus for testing physical characteristics, especially rolling contact fatigue resistance of materials,” Docket No. P-5978.5/G-5978; Washington, D.C. 20231: Commissioner of Patents and Trademarks, Approved (2002).

[35] M. Kalin, J. Vizintin, A Rolling-Contact Device Using The Ball-On-Flat Testing Principle, J. Amer. Ceram. Soc., submitted 2002.

[36] M. Kalin, J. Vizintin, Effect of grinding direction on rolling performance of silicon nitride ceramics using a new device with a ball on flat testing principle, Applied Mechanics and Engineering, vol. 4, special issue "NCBS '99", 1999, 225-230.

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3.3 Practical value of the project

3.3.1 Indicate the practical problems which the study will address. Extensive investigations on hard coatings under sliding conditions led to many important findings on the required properties and deposition parameters of hard coatings and substrates, which resulted in improved mechanical and tribological properties of these surfaces. However, from conventional steel- to-steel rolling contacts it is known that rolling failure mechanisms are quite different compared to sliding contacts. When changing the material, critical factors are also changed, which was, for example, clearly found in the past for hybrid- and all-ceramic bearings. Only the extensive investigations in this area made reliable and very successful use of these components under specific working conditions possible. In analogy, it is reasonable to expect, and current studies confirm this, that in the case of coated surfaces, the acting rolling and combined rolling-to-sliding failure mechanisms will also be different. In particular, according to our anticipation, the critical factors/parameters will be different. Therefore, for the successful and reliable operation of coated bearings and gears much more information and better understanding of the failure mechanisms is absolutely necessary in order to achieve their reliable and efficient use in exploitation. As discussed before, due to amount of rolling bearings and gears, and overall achievements of the coated surfaces in last decade, there exist a great potential that this could actually happen.

3.3.2 Indicate, if possible, the economic benefit expected from the research

The economic benefit of the study is hard to predict, but could be extremely large. As mentioned several times before, the rolling bearings and mechanical power transmissions market is one of the biggest in the world. We cannot avoid having rolling bearings in almost every device in our industry and also everyday life. So even a small portion of this market being replaced by high-tech coated components could have a great economic effect. Moreover, the coated bearings can be the only or at least much better solution for many applications, similar as hybrid and all-ceramic bearings became in their high-speed or high-temperature applications. These affects are difficult to quantify economically at this stage. For coated bearings and gears, starvation of lubricants, dry-running bearings, level of friction or electrical charges in conventional applications and problems can be the exploitation opportunity. The strive towards lower energy consumption is evident for all of the society and the implementation of coated bearings and gear transmissions with predictable performance will be significant factor towards decreased friction and energy consumption. Finally, but not le ss importantly, the environmental issues and conservation of resources are becoming more and more important. DLC coatings can offer a good performance on lower-quality substrate materials, which are usually less demanding for amount of rare alloying elements, less energy is consumed during production, etc.

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3.4 Plan of research Joint plan of the project, Participant 1 – 4, is given. Separate contributions per each partner are provided in Outline and schedule of work

3.4.1 Description of the approach applied in the study

The study will be performed at three levels; The first will be a long-term parametric study using only few variations of materials, but different working and tribological parameters, to asses their effect on acting failure mechanisms. The second level will be a comparison and verification in which various materials, deposition parameters, thickness, etc. will be investigated, but at only few selected – the most relevant - working conditions. In this way, the effect of working parameters, which are assumed to be more important for the generic failure modes (type of failure and parametric effects) will be investigated, but also the effect of materials, like microstructure, hardness, coating adhesion, roughness, lay direction, thickness, etc.., which are more important for the optimization of the system. Therefore, basic knowledge on failure mechanisms supported with practical consideration and optimization parameters will be assessed. Due to practical verification of modeled tribological experiments by using real rolling bearing and gear systems the bearing- and gear steel substrate will be used, properly hardened with nice surface finish to support the hard coating at high stresses and strains and prevent it's flaking. For comparison, another type of steel substrate will be used to verify the observed behavior. Two different DLC coatings with different thickness will be used and investigated in this project. The rolling- and rolling- to-sliding contact tests will be performed using the own-designed test rigs. In the rolling tests, the investigated specimens will be coated flats, while the counter-rolling elements will be a standard steel bearing-balls. In analogy, sliding- to-rolling specimen materials will be selected. Testing conditions as substrates manufacturing lay direction and roughness, velocity, load, pressure, and number of cycles will be determined based on pre-screening test. All the experiments will be performed under monitored room-environment conditions. Experiments will be run in two modes; continuous, to obtain the life until surface failure and intermediate-stopping mode, to evaluate initiation and progress of wear and/or cracks. Numerical simulations of stresses, in particular maximum shear stresses, and power transmittable, based on experimentally obtained frictional forces, will be used to support surface and subsurface observations and allow determination of the correlation between the numerical and experimental evidences. The coefficient of friction will be monitored throughout the tests and in some pre-selected cycles the friction force will be monitored during a single cycle, to be able to evaluate the effect of friction, and consequently shear stresses, on location of failure origination and propagation more accurately and with a higher level of confidence. All tests will be repeated and statistically evaluated. Surface and sub-surface cross-sectioning analyses will be routinely performed using the optical and electron microscope, while for the particular purposes that could be found during the progress of the project, other techniques will also be used, as

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appropriate. Several commonly used material characterization techniques will also be applied prior the materials will be used in the experiments, and if necessary, also after the tests. Finally, the third level will concern industrial verification in industrial test rigs in co-operation with the participating companies. Volvo Car’s role will be to perform full scale verification testing. Volvo Technology role will be primarily to analyze performed tests tribochemically and morphologically and take care on industrial-relevance issues.

Participant 1

3.4.2 Outline of work plan and time schedule 1-3 month literature survey, discussions with partners for joint actions 3-6 month upgrade of the test rig controlling PC software for during-

single-cycle monitoring of the coefficient of friction 6-9 month selection of substrates and DLC coatings and preparation of

the test samples 9-12 month pre-screening tests and numerical verification, determination

of test parameters 12 month control point, preparation of annual report 12-18 month rolling contact testing (failure mode study) 18-24 month surface and sub-surface analyses 24 month control point, preparation of annual report 24-30 month rolling contact testing (materials optimization study) 30-36 month surface and sub-surface analyses, final analyses of data and preparation for the final report 36 month final report

3.4.3 Staff required (graduates and technicians only)

1 Ph.D. student 1 technician

Participant 2

3.4.4 Outline of work plan and time schedule 1-3 month literature survey, discussions with partners for joint actions 3-6 month upgrading and modifications of the experimental equipment

and software for the project purposes 6-9 month selection of substrates and DLC coatings and preparation of

the analyses procedures and samples 9-12 month power transmission requirements, computational verifications,

industrial scale needs and correlations 12 month control point, preparation of annual report 12-24 month Surface analyses for failure mode study 24 month control point, preparation of annual report 24-30 month Surface analyses for optimization and verification tests 30-36 month final analyses of data and preparation for the final report

36 month final report

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3.4.5 Staff required (graduates and technicians only) /

Participant 3

3.4.6 Outline of work plan and time schedule 1-3 month literature survey, discussions with partners for joint actions 3-6 month upgrading and modifications of the test rigs and software for

the project purposes 6-9 month selection of substrates and DLC coatings and preparation of


of test parameters 12 month control point, preparation of annual report 12-24 month Full-scale bearing and gear tests (failure mode study) 24 month control point, preparation of annual report 24-30 month Full-scale optimization and verification tests 30-36 month final analyses of data and preparation for the final report

36 month final report

3.4.7 Staff required (graduates and technicians only) /

Participant 4:

3.4.8 Outline of work plan and time schedule 1-3 month literature survey, discussions with partners for joint actions 3-6 month repetition and robustness testing on the rough friction test rig,

optimizing topography characterization 6-9 month selection of substrates and DLC coatings and preparation of


of test parameters 12 month control point, preparation of annual report 12-18 month sliding-to-rolling contact testing (failure mode study) 18-24 month surface roughness and sub-surface analyses 24 month control point, preparation of annual report 24-30 month sliding-to-rolling contact testing (materials optimization study) 30-36 month surface roughness and sub-surface analyses, final analyses of data and preparation for the final report 36 month final report

3.4.9 Staff required (graduates and technicians only)

1 Ph D student

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3.5 Experience and Resources of the Institutions

3.5.1 Participant 1

Brief summary of previous or current work in similar or related fields. (1) In the frame of COST 516 – Tribology project (P.I.: dr. Jože Vižintin), CTD group was working on Sliding and Pitting wear properties of Induction hardened, conventional plasma nitrided and pulse plasma nitrided low alloy steels and in co-operation with VTT Institute, Finland, and Uppsala University, Sweden on Influence of substrate pre-treatment on the tribological properties of hard coatings under dry sliding. Results of that work showed improved sliding and pitting wear resistance of low alloy steels when plasma nitrided. It was also shown that substrate treatment has a crucial influence on the tribological behavior of hard coated surfaces. (2) In national and international projects (NIST, USA), (P.I. dr. Jože Vižintin) The effect of surface finish and lubricants on rolling contact fatigue of silicon nitride was investigated. Results pointed out the importance of type and direction of surface finish on the rolling fatigue of silicon nitride. On the other hand new lubricant additives should be developed for ceramic materials in order to substantially improve their rolling contact fatigue properties. During this work, an innovative own-made test rig for rolling contact performance of materials has been developed with several advances compared to conventional RCF tester. The device and testing procedure were patented in Europe and USA. (3) Currently, CTD group (P.I. dr. Mitjan Kalin) is working on a EC 5th Framework Project, i.e. Lubricoat – Environmentally friendly lubricants and low friction coatings. In co-operation within 8 EU partners the innovative, and high-tech tribological material combinations with a positive impact on the environment, including the various DLC low friction coatings and bio-degradable synthetic and natural lubricants, are investigated and being developed.

Publications in the last two years.

I. Journal Papers

1. KALIN, Mitjan, VIŽINTIN, Jožef, VLEUGELS, Jozef, VAN DER BIEST, Omer. Influence of mechanical pressure and temperature on the chemical interaction between steel and silicon nitride ceramics. J. mater. res., 2000, vol. 15, no. 6, 1367-1376.

2. KALIN, Mitjan, VIŽINTIN, Jožef, VLEUGELS, Jozef, VAN DER BIEST, Omer. Chemical reactivity of silicon nitride with steel and oxidised steel between 500 and 1200°C. Mater. sci. eng., A Struct. mater. : prop. microstruct. process., 2000, vol. A281, issue 1/2, 28-36.

3. KALIN, Mitjan, VIŽINTIN, Jožef. Use of equations for wear volume determination in fretting experiments. Wear. 2000, vol. 237, issue 1, 39-48.

4. ŠRAJ, Robert, VIŽINTIN, Jožef, SVOLJŠAK, Marta, FELDIN, Marta. Rapidly biodegradable hydraulic fluids on the basis of rapeseed oil. Lubr. eng., 2000, vol. 56, no. 4, 34-39.

5. ŠRAJ, Robert, SVOLJŠAK, Marta, FELDIN, Marta, VIŽINTIN, Jožef. Rapidly biodegradable hydraulic fluids on the basis of rapeseed oil. Goriva maziva, 2000, god. 39, br. 1, 11-23.

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6. ARNŠEK, Aleš, VIŽINTIN, Jožef. Lubricating properties of rapeseed-based oils. J. synth. lubr., 2000, vol. 16, no. 4, 281-296.

7. VIŽINTIN, Jožef, ARNŠEK, Aleš, PLOJ, Anton. Lubricating properties of rapeseed oils compared to mineral oils under a high load oscillating movement. J. synth. lubr., 2000, vol. 17, no. 3, 201-217.

8. PODGORNIK, Bojan, VIŽINTIN, Jožef, RONKAINEN, Helena, HOLMBERG, Kenneth. Wear resistance of DLC coating deposited on pretreated AISI 4140 steel. Adv. eng. mater. 2000, vol. 2, no. 7, 444-448.

9. PODGORNIK, Bojan, VIŽINTIN, Jožef, LESKOVŠEK, Vojteh, WÄNSTRAND, Olle, LARSSON, Mats, HOGMARK, Wear properties of plasma nitrided and hard coated 42CrMo4 steel. Mater. tehnol., jan.-apr. 2000, vol. 34, Vol. 1/2, 17-21.

10. VEZJAK, Anton, VIŽINTIN, Jožef, OBERŽAN, Martina. Parameter PV lim as a face material evaluation criteria of mechanical seals. Mater. tehnol., maj-avg. 2000, vol. 34, no. 3/4, 143-146.

11. PODGORNIK, Bojan, VIŽINTIN, Jožef, LESKOVŠEK, Vojteh, RONKAINEN, Helena, HOLMBERG, Kenneth. Tribological properties of DLC-coated plasma-nitrided steel. Mater. tehnol., nov.-dec. 2000, vol. 34, no. 6, 375-379.

12. PODGORNIK, Bojan, VIŽINTIN, Jožef, RONKAINEN, Helena, HOLMBERG, Kenneth. Friction and wear properties of DLC-coated plasma nitrided steel in unidirectional and reciprocating sliding. Thin solid films. 2000, vol. 377/378, issue 1/2, 254-260.

13. VEZJAK, Anton, VIŽINTIN, Jožef. Computer controlled test rig for tribological research of materials for mechanical seals. Mater. tehnol., jan.-apr. 2000, vol. 34, no. 1/2, 99-102.

14. TRSTENJAK, Marjan, VIŽINTIN, Jožef, CERKOVNIK, Janko. Changes in maintenance program at ironworks in Slovenia. Maintenance journal, 2000, vol. 13, no. 2, 42-45.

15. PODGORNIK, Bojan, VIŽINTIN, Jožef. Tribological properties of plasma nitrided AISI 4140 steel under dry and lubricated sliding conditions. Tribotest 2000, vol. 6, no. 4, 357-371.

16. KALIN, Mitjan, VIŽINTIN, Jožef. Comparison of different theoretical models for the flash temperature calculation under fretting conditions. Tribol. int.. 2001, vol. 34, no. 12, special issue "NORDTRIB 2000", 831-839.

17. KALIN, Mitjan, VIŽINTIN, Jožef. High temperature phase transformations under fretting conditions. Wear, 2001, vol. 249, no. 3/4, 172-181.

18. NOVAK, Saša, KALIN, Mitjan, KOSMAC, Tomaž. Chemical aspects of wear of alumina ceramics. Wear. 2001, vol. 250, no. 1/12, 318-321.

19. KALIN, Mitjan, VIŽINTIN, Jožef. A tentative explanation for the tribochemical effects in fretting wear. Wear. 2001, vol. 250, no. 1/12, 681-689.

20. KALIN, Mitjan, VIŽINTIN, Jožef. Tribochemical changes in steel and ceramics under fretting conditions. Stroj. vestn., 2001, vol. 47, no. 3, 114-128.

21. KALIN, Mitjan, VIŽINTIN, Jožef. Calculating the contact temperature for lubricated and dry fretting conditions. Stroj. vestn., 2001, vol. 47, no. 3, 129-139.

22. PODGORNIK, Bojan, KALIN, Mitjan, VIŽINTIN, Jožef, VODOPIVEC, Franc. Microstructural changes and contact temperatures during fretting in steel-steel contact. J. tribol., 2001, vol. 123, no. 4, 670-675.

23. VIŽINTIN, Jožef, ARNŠEK, Aleš. Tribological properties of rapeseed oils compared to mineral oils - basics, test methods and test oil selection (part 1). Stroj. vestn., 2001, vol. 47, no. 3, 140-146.

24. PODGORNIK, Bojan, VIŽINTIN, Jožef. Influence of substrate treatment on the tribological properties of DLC coatings. Diamond and related materials, 2001, vol. 10, no. 12, 2232-2237.

25. PODGORNIK, Bojan, VIŽINTIN, Jožef. Wear resistance of pulse plasma nitrided AISI 4140 and A355 steels. Mater. sci. eng., A Struct. mater. : prop. microstruct. process.. 2001, vol. A315, issue 1/2, 28-34.

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26. PODGORNIK, Bojan, VIŽINTIN, Jožef. Influence of substrate pretreatment on the tribological properties of hard coatings. Stroj. vestn., 2001, vol. 47, no. 4, 152-162.

27. PODGORNIK, Bojan, VIŽINTIN, Jožef, LESKOVŠEK, Vojteh. Wear resistance of plasma nitrided structural steel. Stroj. vestn., 2001, vol. 47, no. 4, 163-173.

28. ARNŠEK, Aleš, VIŽINTIN, Jožef. Tribological properties of rapeseed oils compared to mineral oils - results of mechanical-dynamic investigations (part 2). Stroj. vestn., 2001, vol. 47, no. 4, 174-185.

29. ARNŠEK, Aleš, UDOVC, Alma, VIŽINTIN, Jožef. Tribological properties of rapeseed oils compared to mineral oils - results of physical and chemical analysis (part 3). Stroj. vestn., 2001, vol. 47, no. 5, 217-225.

30. PODGORNIK, Bojan, VIŽINTIN, Jožef. Sliding and pitting wear resistance of plasma and pulse plasma nitrided steel. Surf. eng., 2001, vol. 17, no. 4, 300-304.

31. PODGORNIK, Bojan, VIŽINTIN, Jožef, WÄNSTRAND, Olle, LARSSON, Mats, HOGMARK, Sture, RONKAINEN, Helena, HOLMBERG, Kenneth. Tribological properties of plasma nitrided and hard coated AISI 4140 steel. Wear. [Print ed.], 2001, vol. 249, issue 3/4, 254-259.

32. PODGORNIK, Bojan. Coated machine elements - fiction or reality?. Surf. coat. technol.. 2001, vol. 146/147, 318-323.

33. KALIN, Mitjan, JAHANMIR, Said, IVES, Lewis K. Effect of counterface roughness on abrasive wear of hydroxyapatite. Wear. 2002, no. 9/10, vol. 252, 679-685.

34. PODGORNIK, Bojan, VIŽINTIN, Jože. Rolling contact properties of ta-C coated low alloy steel. Surf. Coat. Technol., 2002, Vol. 157, 257-261.

35. VEZJAK, Anton, VIŽINTIN, Jožef. The influence of lubricating conditions on the tribological behaviour of face materials in mechanical seals. Mater. tehnol., 2002, vol. 36, no. 1/2, 43-47.

II. 2. Conference papers

1. KALIN, Mitjan, VIŽINTIN, Jožef. Comparison of different theoretical

models for the flash temperature calculation under fretting conditions. V: ANDERSSON, Peter (ur.), RONKAINEN, Helena (ur.), HOLMBERG, Kenneth (ur.). 9th Nordic Symposium on Tribology NORDTRIB 2000, Porvoo, Finland, 11 - 14 June 2000, 320-326.

2. KALIN, Mitjan, VIŽINTIN, Jožef. High temperature phase transformations under fretting conditions. V: ANDERSSON, Peter (ur.), RONKAINEN, Helena (ur.), HOLMBERG, Kenneth (ur.). 9th Nordic Symposium on Tribology NORDTRIB 2000, Porvoo, Finland, 11 - 14 June 2000, 638-645.

3. KALIN, Mitjan, VIŽINTIN, Jožef. Comparison of different theoretical models for the flash temperature calculation under fretting conditions. V: AIHARA, Satoru (ur.), GOTO, Hozumi (ur.), MASUKO, Masabumi (ur.), MIZUTANI, Yoshiyuki (ur.), MORI, Shigeyuki (ur.), SUZUKI, Mineo (ur.), IZUMI, Naoshi (ur.), ICHIMARU, Kazunori (ur.). ITC Nagasaki 2000 : proceedings of the International Tribology Conference, Nagasaki, October 29 - November 2, 2000, 403-406.

4. KALIN, Mitjan, VIŽINTIN, Jožef. A fretting wear mechanism of high temperature phase transformed material. V: AIHARA, Satoru (ur.), GOTO, Hozumi (ur.), MASUKO, Masabumi (ur.), MIZUTANI, Yoshiyuki (ur.), MORI, Shigeyuki (ur.), SUZUKI, Mineo (ur.), IZUMI, Naoshi (ur.), ICHIMARU, Kazunori (ur.). ITC Nagasaki 2000 : proceedings of the International Tribology Conference, Nagasaki, October 29 - November 2, 2000, 407-411.

5. PODGORNIK, Bojan, VIŽINTIN, Jožef, KALIN, Mitjan. Influence of substrate pre-treatment on the tribological properties of DLC coatings. V: AIHARA, Satoru (ur.), GOTO, Hozumi (ur.), MASUKO, Masabumi (ur.), MIZUTANI, Yoshiyuki (ur.), MORI, Shigeyuki (ur.), SUZUKI, Mineo (ur.),

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IZUMI, Naoshi (ur.), ICHIMARU, Kazunori (ur.). ITC Nagasaki 2000 : proceedings of the International Tribology Conference, Nagasaki, October 29 - November 2, 2000, 1083-1087.

6. VEZJAK, Anton, VIŽINTIN, Jožef. The influence of the duty parameter G on the PV limit in mechanical seals. V: FLITNEY, Robert K. (ur.). 16th International Conference on Fluid Sealing : papers presented at the 16th International Conference on Fluid Sealing: Successful sealing : held in Brugge, Belgium on 18-20 September 2000, 411-420.

7. NOVAK, Saša, VIŽINTIN, Jožef. Electrokinetic aspect of friction and wear of oxide ceramics. V: JESSEN, Todd (ur.), USTUNDAG, Ersan (ur.). 24th Annual Conference on Composites, Advanced Ceramics, Materials, and Structures: B : January 23-28, 2000, Cocoa Beach, Florida, (Ceramic engineering & science proceedings, Vol. 21, issue 3-4), 407-414.

8. PODGORNIK, Bojan, VIŽINTIN, Jožef, WÄNSTRAND, Olle, LARSSON, Mats, HOGMARK, Sture, RONKAINEN, Helena, HOLMBERG, Kenneth. Tribological properties of plasma nitrided and hard coated AISI 4140 steel. V: ANDERSSON, Peter (ur.), RONKAINEN, Helena (ur.), HOLMBERG, Kenneth (ur.). 9th Nordic Symposium on Tribology NORDTRIB 2000, Porvoo, Finland, 11 - 14 June 2000, 457-468.

9. VIŽINTIN, Jožef, KRŽAN, Boris. New biodegradable universal tractor transmission oil based on rapeseed oil. V: IGARTUA, Amaya (ur.), ALBERDI, Alberto (ur.). Proceedings of the 3rd COST 516 Tribology Symposium : Eibar, Spain, 18 and 19 May 2000, 54-65.

10. PODGORNIK, Bojan, VIŽINTIN, Jožef. Sliding and pitting wear resistance of plasma and pulse plasma nitrided AISI 4140 steel. V: IGARTUA, Amaya (ur.), ALBERDI, Alberto (ur.). Proceedings of the 3rd COST 516 Tribology Symposium : Eibar, Spain, 18 and 19 May 2000, 263-270.

11. SOVIC, Boštjan, VIŽINTIN, Jožef. Determination of indicators of tooth flanks pitting failure on gears by vibration monitoring. V: GUIDATI, Gianfranco (ur.), HUNT, Hugh (ur.), HEISS, Alois (ur.). Seventh International Congress on Sound and Vibration : proceedings, Garmisch-Partenkirchen Congress Center, Germany, 4-7 July 2000, 515-522.

12. VEZJAK, Anton, VIŽINTIN, Jožef. Experimental study on the relationship between lubrication regime and the performance of mechanical seals. Preprint no. 00-TC-20. V: STLE preprints presented at the ASME/STLE Tribology Conference in Seattle, Washington, October 1-4, 2000, 1-6.

13. ARNŠEK, Aleš, VIŽINTIN, Jožef. Pitting resistance of rapeseed-based oils. V: BARTZ, Wilfried J. (ur.). 12th International Colloquium, Esslingen, Germany, January 11-13, 2000. Tribology 2000 - Plus, 143-148.

14. PODGORNIK, Bojan, VIŽINTIN, Jožef. Sliding wear properties of plasma nitrided steels. V: BARTZ, Wilfried J. (ur.). 12th International Colloquium, Esslingen, Germany, January 11-13, 2000. Tribology 2000 - Plus, 1663-1670.

15. KALIN, Mitjan, VIŽINTIN, Jožef. Effects of the contact surface properties on the flash temperature calculation and wear behaviour. V: International Congress on Advanced Materials, their Processes and Applications, Munich, Germany, October 1-4, 2001, p. 1-7.

16. PODGORNIK, Bojan, VIŽINTIN, Jožef. Load carrying capacity of duplex treated low alloy steel under rolling and sliding contact. V: FRANEK, Friedrich (ur.), BARTZ, Wilfried J. (ur.), PAUSCHITZ, Andreas (ur.). Tribology 2001 : plenary and session key papers from the 2nd World Tribology Congress, Vienna, Austria, 3 - 7 September 2001, Scientific achievements, Industrial applications, Future challenges, 89-92.

17. KRŽAN, Boris, VIŽINTIN, Jožef. Biološko razgradljiva maziva kot alternativa mazivom mineralnega izvora. V: POJE, Tomaž (ur.). Zbornik simpozija Trendi v razvoju kmetijske tehnike, Radenci, 14. in 15. junij 2001, str. 27-34.

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18. PODGORNIK, Bojan, VIŽINTIN, Jožef. Wear resistance of duplex treated steel. V: KUZMAN, Karl (ur.). 3rd International Conference on Industrial Tools ICIT 2001, Rogaška Slatina, Celje, Slovenia, April 22-26, 2001, 179-182.

19. DOLINŠEK, Slavko, ŠUŠTARŠIC, Borivoj, VIŽINTIN, Jožef. Cutting forces as a measure for the self-lubricating of some hot-pressed composites. V: CHANDRA, T. (ur.), HIGASHI, K. (ur.), SURYANARAYANA, C. (ur.), TOME, C. (ur.). 3rd International Conference on Processing & Manufacturing of Advanced Materials, Las Vegas, Nevada, USA, December 4-8, 2000. THERMEC '2000 : processing, fabrication, properties, applications. 2001, 6.

20. KALIN, Mitjan, NOVAK, Saša, VIŽINTIN, Jožef. Wear and friction behavior of alumina ceramics in aqueous solutions with different pH. V: 10th Nordic Symposium on Tribology - NORDTRIB 2002, Stockholm, Sweden, June 9-12, 2002, 10 p.

21. PODGORNIK, Bojan, HOGMARK, Sture, SANDBERG, Odd, LESKOVŠEK, Vojteh. Wear resistance and anti-sticking properties of duplex treated forming tool steel. V: 10th Nordic Symposium on Tribology - NORDTRIB 2002, Stockholm, Sweden, June 9-12, 2002, 12 p.

22. PODGORNIK, Bojan, JACOBSON, Staffan, HOGMARK, Sture. Advantages of DLC coating of one part, as compared to both or none in boundary lubricated steel components. V: 10th Nordic Symposium on Tribology - NORDTRIB 2002, Stockholm, Sweden, June 9-12, 2002, 12 p.

23. KRŽAN, Boris, VIŽINTIN, Jožef. New biodegradable universal tractor transmission oil based on vegetable oil. V: 10th Nordic Symposium on Tribology - NORDTRIB 2002, Stockholm, Sweden, June 9-12, 2002, 10 p.

24. HOGMARK, Sture, JACOBSON, Staffan, PODGORNIK, Bojan. On the evaluation of coatings for mechanical components. V: GRÁCIO, José (ur.), DAVIM, Paulo (ur.), HUA FAN, Qi (ur.), ALI, Nasar (ur.). 8th Portuguese Tribology Conference, Aveiro, May 8-9, 2002. New developments on tribology: theoretical analysis and application to industrial processes, 25-38.

25. PEZDIRNIK, Jožef, VIŽINTIN, Jožef. Some parameters and properties influencing on friction of spool-sliding valves. V: 3rd International Fluid Power Conference (3rd IFK), Aachen, Germany, March 5-6, 2002, 457-468.

26. KRŽAN, Boris, VIŽINTIN, Jožef. Vegetable based oil as a gear lubricant. V: International Conference on Gears : [Tagung München], March 13-15, 2002, 465-478.

27. PODGORNIK, Bojan, VIŽINTIN, Jožef. Wear resistance of plasma and pulse plasma nitrided gears. V: International Conference on Gears : [Tagung München], March 13-15, 2002, 593-601.

28. SPRECIC, Denijal, SPRECIC, Elis, VIŽINTIN, Jožef, SLUGA, Alojzij. Examples of an expert system in the estimation of the quality of lubricants. V: MARJANOVIC, Dorian (ur.). Proceedings of the 7th International Design Conference DESIGN 2002, Cavtat, Dubrovnik, Croatia, May 14-17, 2002, 417-422.

III. Patents

1. M. Kalin, J. Vizintin, “Apparatus for testing rolling contact fatigue resistance

of materials with possible interruptions,” Docket No. P-5978.6/G-5978; Washington, D.C. 20231: Commissioner of Patents and Trademarks, Approved (2002).

2. J. Vizintin, M. Kalin, “Apparatus for testing physical characteristics, especially rolling contact fatigue resistance of materials,” Docket No. P-5978.5/G-5978; Washington, D.C. 20231: Commissioner of Patents and Trademarks, Approved (2002).

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IV. Books

1. M. Kalin, J. Vižintin, K. Dohda, S. Jahanmir, Eds., Tribology of mechanical systems – a guide to present and future technologies, ASME Press, In press.

Staff and equipment available at the laboratory for the efficient execution of the proposed research work. 1. Staff

1 Professor (Ph.D.) 3 Assistant Professors (Ph.D.) 3 Ph.D. students 1 Technician

2. Equipment • Rolling contact ball-on-flat test rig • Optical Microscope with CCD camera • SEM Microscope with EDS • Stylus 3D profilometer • Residual stress measurement system • Hardness tester • Equipment for metalographic preparation of samples, etc.

3.5.2 Participant 2 Brief summary of previous or current work in similar or related fields.

Volvo Technology Corporation, VTEC, is a corporate, task driven, R&D unit operationally integrated in the Volvo groups’s different business areas and related companies. VTD provides expert R&D service to the both the present Volvo group and Volvo Cars. Expertise is based on an integration of know-how relating to a large number of basic disciplines. Volvo Technological Development is exploiting the Group synergy opportunities in a number of development areas of large importance to Volvo's different business branches. VTEC has had a long fruitful cooperation Volvo Car Transmission and Professor Rosén on final machning and coating of gears.

Publications 1. Manganese Phosphating and surface roughness consequences, H.

Westberg, P H Nilsson, B-G Rosén and B Stenbom, 26th Leeds-Lyon symposium on tribology, Leeds, UK 1999

2. On finishing and phosphating of gear surfaces, Henrik Westberg, Göteborg 2000, PTA 00:03, ISBN 91-7197-905-0

3. An experimental study on the effect of surface topography on rough friction in gears, Li Xiao, Naser Amini and B.-G. Rosén, Proceedings of The JSME International Conference on Motion and Power Transmissions, Fukuoka, Japan, NOV 2001

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4. Rough friction test rig, Li Xiao, Chalmers, PTI 00:01 5. A study on the effect of surface topography on rough friction in roller

contact, L Xiao, B-G Rosén, N Amini and P H Nilsson, 10th Nordic symposium on tribology, Stockholm, Sweden, 2002

Staff and equipment available at the laboratory for the efficient execution of the proposed research work.

Qualification of personnel assigned to the project: The personnel at VTD are all scientists with at least 10 years of working experience of tribological design of components for the automotive industry. Per H Nilsson, MSc, is responsible for the department Surface Engineering, has a long experience of tribological testing. Claes Frennfelt, Tech. Lic., is responsible for thin film technology. Bertil Stenbom, PhD, is the microanalytical expert. Main RTD facilities. As partner to producers of vehicles VTEC disposes of test facilities on different levels: • Microanalytical equipment; XPS, ToFSIMS, SEM/EDS,

TEM/STEM/EDS, 3-D Profilometers, Scratch Tester, Indenters, Microscopes etc.

• Equipment for quality control of lubricants; ICP, FT-IR etc.

3.5.3 Participant 3 Brief summary of previous or current work in simila r or related fields.

Volvo Cars, Transmission Development, VCC, is responsible for the development of transmissions within Volvo Cars. Volvo Cars, Transmission Development, has a long cooperation with VTEC and Professor Rosén on machining and coating of gears.

Publications 1. Manganese Phosphating and surface roughness consequences, H.

Westberg, P H Nilsson, B-G Rosén and B Stenbom, 26th Leeds-Lyon symposium on tribology, Leeds, UK 1999

2. On finishing and phosphating of gear surfaces, Henrik Westberg, Göteborg 2000, PTA 00:03, ISBN 91-7197-905-0

3. An experimental study on the effect of surface topography on rough friction in gears, Li Xiao, Naser Amini and B.-G. Rosén, Proceedings of The JSME International Conference on Motion and Power Transmissions, Fukuoka, Japan, NOV 2001

4. Rough friction test rig, Li Xiao, Chalmers, PTI 00:01 5. A study on the effect of surface topography on rough friction in roller

contact, L Xiao, B-G Rosén, N Amini and P H Nilsson, 10th Nordic symposium on tribology, Stockholm, Sweden, 2002Staff and equipment available at the laboratory for the efficient execution of the proposed research work.

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Qualification of personnel assigned to the project: The personnel at VCC are all specialists with long of working experience of gear design. Naser Amin, PhD, is responsible for the department Gear Technology, has a long experience of gear surfaces. Kennet Thor is responsible for gear design. Test personnel will active in the latter part of the project. Main RTD facilities. As a producer of vehicles VCC disposes of: • Gear production facilities. • Test facilities of transmissions on different levels.

3.5.4 Participant 4

Brief summary of previous or current work in similar or related fields. Halmstad University, The Functional Surfaces Research Group, School of Business and Engineering, is situated in the south of Sweden on the west-coast. The University has about 6000 students and 450 staff where of 12 full professors are responsible for the education and research in their respectively field. The Functional Surface research group belongs to the cross-disciplinary Department of Economics ant Technology. The recently founded group has a long history of research in the field from Chalmers Surface Geometry Group, a research group at the former Department of Production Engineering, specialized in characterization & manufacturing of functional surface topography. The research activities from this group at Chalmers University of Technology in Göteborg (Sweden’s second largest technical University faculty) are being moved south to Halmstad along with the researchers and projects. The current group consist of 5 researchers (1 full professor Bengt-Göran Rosén, 1 visiting professor Tom R. Thomas and 3 PhD students). Current surface topography projects are funded equally between industry (Volvo, Swedish Steel …) and annual turnover is approximately 3.500kECU, whereof more than 66% is external funding from industry related projects. The researchers had been active in the field of surface manufacturing and characterization of functional surfaces for more than 20 years with international co-operation. The Functional Surfaces research group is one of Europe’s most well equipped surface topography research teams with access to measuring devises worth more than 350KECU ranging from Atomic Force Microscopes for fine detailed measurements along with a 3D interference microscope to 3D stylus and capable for form and roughness measurements in the cm-dm horizontal range. The work carried out by the researchers and the group is internationally known for their work on surface topography and it’s effect upon functional

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performance for a range of applications. The group has experience from the organizing of international conferences and organized the 7’th International Conference on Metrology and Properties of Engineering Surface in 1997 in Göteborg. The group is also active in international standardization of 2D- and 3D-roughness in ISO TC 213 as well as in the corresponding national standardization groups both in Sweden and Great Britain.. Members from the group participated in two recently finished EU 4’th frame work programmes:

• Brite-Euram,”Surface Topography optimisation for the automotive industry”, AUTOSURF, 1998-2001.

• Standards Measurement and Testing “Techniques and applications in surface microtopography”, STANDSURF, 1998-2001.

Current activities: The long-term close co-operation with major Swedish and international companies has ensured that the research not only has a scientific value but also is industrially relevant. The research is currently focused on Automotive- and Plastic- surface applications. The current research in the Automotive field is concentrated to optimization of surface textures for steel sheet forming and painting as well as optimization of transmission and engine components’ surface textures on e.g. gears and engine cylinder-piston surfaces. This on-going research has a long history and has so far produced 5 PhD’s since 1994. Much of the work has been directed at manufacturing process understanding and monitoring the surfaces’ influence on effects like friction, wear, noise emission and visual appearance. Lately attention has been paid to the growing field of mobile communications and the visual appearance of injection moulded components. The study and understanding of the machining of tools for this branch of industry can play an important role for the competition in product finish and surface related product appearance in terms of e.g. colour, and gloss. The group has a long experience in working with Industry and lately a rough friction rig has been designed and built for use in projects in co-operation with Volvo to optimize gear friction and gear noise properties for the transmission.

Publications. 1. Rosén B.-G., On Comparative measurements, to be printed in; E.

Mainsah, J.A. Greenwood, D.G. Chetwynd(ed.) Metrology and Properties of Engineering Surfaces, Kluwer Academic Publishers, Boston, - ISBN 0-412-80640-1, (2001).

2. Rosén B.-G.,Tolerancing and roughness –a need for Harmonisation?, for the Australian meeting 1999, ISO TC 213: Advisory Group, AG5, Future needs for surface texture characterisation, Expert report on the subject : Relationship with existing tolerancing system, January (1999).

3. T.R. Thomas, N. Amini, B.-G. Rosén, Describing the Directional Properties on Machined Surfaces, In: P. McKeown, J. Corbett, M.

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Bonnis, S. Sartori, H. Kunzmann, M. Weck, E. Brinksmeier, W. Preuss, O. Reimer (ed.) Precision Engineering – Nanotechnology, Proceedings of the 1st International euspen Conference, vol. 2, May 31 – June 4, ISBN 3-8265-6085-X, Shaker Verlag GmbH, Aachen, Germany, (1999).

4. T.R. Thomas, N. Amini, B.-G. Rosén, Modelling and Engineering of Honed Microtopography, In: P. McKeown, J. Corbett, M. Bonnis, S. Sartori, H. Kunzmann, M. Weck, E. Brinksmeier, W. Preuss, O. Reimer (ed.) Precision Engineering – Nanotechnology, Proceedings of the 1st International euspen Conference, vol. 2, May 31 – June 4, ISBN 3-8265-6085-X, Shaker Verlag GmbH, Aachen, Germany, (1999).

5. Henrik J. Westberg, Per H. Nilsson, Bengt-Göran Rosén, Bertil Stenbom, Manganese Phosphating of Gears and Surface Roughness Consequence, presented at Chris Taylor, Duncan Dawson (org.) Thinning Films and Tribological Interfaces, 26th Leeds-Lyon Symposium on Tribology, 14th – 17th September, (1999). Published in: D. Dawson (ed.) Thinning Films and Tribological Interfaces, Tribology Series 38, ISBN 0 444 50531 8, Elsevier Science B.V., Amsterdam, The Netherlands, (2000).

6. * T.R. Thomas, B.-G. Rosén, N. Amini, Fractal chatacterisation of the anisotropy of rough surfaces, Wear, No. 232, pp. 41-50, (1999).

7. * T.R. Thomas, B.-G. Rosén, Determination of the Optimum Sampling Interval for Rough contact Mechanics, In: J. Sullivan, S. Chandler, R. Gilson, A. Kapor, A. Menon (org. com.) TISD´99 Tribology of Information Storage Devices, Abstract Book. December 6-8, Santa Clara, USA, (1999). Published in Tribology International, 33, (2000).

8. J. Condeco, L.H. Christensen, S.F. Jörgensen, B.-G. Rosén, A Comparative Study of Image Stitching Algorithms for Surface Topography Measurements, In; M. Dietzsch, H. Trumpold (ed.) Proceedings of the X Internationales Oberflächenkolloquium, Chemnitz, Germany, January 31- February 2, (2000).

9. * J. Condeço, L.H. Christensen and B.-G. Rosén, Software relocation of 3D surface topography measurements, In: K.J.. Stout, L. Blunt (ed.)Transactions of the 8th Int. Conf. on Metrology and Properties of Engineering Surfaces, April 26-28, University of Huddersfield, Huddersfield, England, (2000). To be Published in Int. J. of Machine Tools & Manufacture, (2001).

10. * B.-G. Rosén, T.R Thomas, Relationship of -the plasticity index to machining parameters, In: K.J.. Stout, L. Blunt (ed.)Transactions of the 8th Int. Conf. on Metrology and Properties of Engineering Surfaces, April 26-28, University of Huddersfield, Huddersfield, England, (2000). To be Published in Int. J. of Machine Tools & Manufacture, (2001).

11. * F. Sacerdotti, BJ Griffiths, F. Benati, C. Butler, M. Jonasson, G. Liraut, BG Rosén, J. Scheers, P. Scott, DJ Wentink, Hardware Variability in the Three-Dimensional Measurement of Autobody Steel Panel Surfaces, In: K.J.. Stout, L. Blunt (ed.)Transactions of the 8th Int. Conf. on Metrology and Properties of Engineering Surfaces, April 26-28, University of Huddersfield, Huddersfield, England, (2000). To be Published in Int. J. of Machine Tools & Manufacture, (2001).

12. K.J. Stout, P.H. Osanna, B.-G. Rosén, The Structure for functional control of manufacturing proceses, submitted end of December to IQMM’2001 International NAISO Symposium on Information Science Innovations in Intelligent Quality Management and Metrology, Dubai February (2001).

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13. Hongjun Wang, B.G. Rosén, J. Rosén, Inspection Information Modelling based on STEP in Agile manufacturing, In T. Kjellberg (org.) Proceedings of The Intrnational CIRP Design Seminar -Design in the New Economy, 6-8 June, Stockhom, pp. 335-339, (2001).

14. Wihlborg, D. Wiklund, B.-G. Rosén, R. Crafoord, Surface Indention Test (SIT) for friction prediction in mixed lubrication of coated steel sheets, presented at Chris Taylor, Duncan Dawson (org), 28th Leeds-Lyon Symposium on Tribology, 3rd – 7th September, Wienna, (2001).

15. Wihlborg, D. Wiklund, B.-G. Rosén, The Influence of Lubricants Kinnematic Viscosity and Steel Sheet Surface Topography in a Bending Unde Tension Friction Test, presented at: The 2nd World Tribology Congress, F. Franek, W.J. Baritz, A. Paushitz (org), 3rd – 7th September, Wienna, (2001).

16. Henrik Westberg, On finishing and phosphating of gear surfaces, Göteborg 2000, PTA 00:03, ISBN 91-7197-905-0.

17. Li Xiao, Naser Amini and B.-G. Rosén , An experimental study on the effect of surface topography on rough friction in gears, Proceedings of The JSME International Conference on Motion and Power Transmissions, Fukuoka, Japan, (2001).

18. Li Xiao , Rough friction test rig, Chalmers, PTI 00:01. 19. L Xiao, B-G Rosén, N Amini and P H Nilsson, A study on the effect of

surface topography on rough friction in roller contact, 10th Nordic symposium on tribology, Stockholm, Sweden, (2002).


• 1 full professor (Bengt-Göran Rosén) • 1 visiting professor (Tom R. Thomas) • 3 PhD students

Main RTD facilities:

• Atomic Force Microscopes for fine detailed measurements • 3D interference microscope • 3D stylus • form and roughness measurements in the cm-dm horizontal range. • Tribotesters for rolling and sliding • Rough friction rig for optimizing gear friction and gear noise properties

for the transmission.

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3.6 Co-operation

name of partners and group project leader, exchange of information Partners within joint agreed actions: 1. Dr. Mitjan Kalin, Center for Tribology and Tech. Diag., Univ. of Ljubljana, Slovenia 2. Per Nilsson Henrik, VOLVO Tech. Development Corp., Göteborg, Sweden: 3. Dr. Naser Amini, Manager, Volvo Car Corporation, Göteborg, Sweden 4. Professor Bengt-Göran Rosén, Halmstad University, Halmstad, Sweden Other Co-operating partners (discussion in progress): 1. Jan Meneve, Karel Van Acker, VITO, Mol, Belgium: (discussion in progress) Additional coating characterisation, coating modifications and parameters 2. Victoria Wikstrom, SKF coated bearings, Gothenburg, Sweden, and Piet Lugt, Aidan Kerrigan, SKF Research centre ERC, Holland: (discussion in progress) Supplement rolling bearings tests and data, coating selection issues 3. Jan Suchánek, SVUM Inc., Prague, Czech Republic

Comparative rolling test method, comparative rolling tests, substrate material issues

3.7 Research topics:

The Action COST 532 is organized in five working groups (described in annex 2): - Lubricant chemistry and chemomechanical effect

- Scale aspects, micro-and nanomechanisms - Rheology - Materials and coatings - Evaluation testing Please indicate the WG your proposal belong to. Our proposal belongs to WG - Materials and coatings

C532-PP-M14-01-02

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