The Importance of Tribology in Demanding Industrial...

© IK4-TEKNIKER 2016

The Importance of Tribology in Demanding Industrial ApplicationsDr. Amaya Igartua, Dr. R. Bayon, Dr. A. Aranzabe, J. Laucirica, [email protected];

mailto:[email protected]


CONTENT

1. IK4-TEKNIKER general presentation

2. Introduction Tribology

3. Tribology in aggressive environments

4. Tribology of mechanical components

5. High temperature Tribology

6. Tribology of soft materials

7. Tribolubrication

8. Conclusions


IK4-TEKNIKER


RELEVANCE OF TRIBOLOGY


THE TRIBOLOGY UNIT• A well established unit with 35 years experience in Tribology

• National and European Reference in Tribology:

• Participation in more than 120 projects (EU, nacionals y regionals) specific

around tribology

• >250 contributions in reviews, congress and especialized books. 3 patents

• Congress Organization Collaboration: IBERTRIB, LUBMAT, World

Tribology Congress

• Participation in several national and international associations: International

Wearcheck group, EUMAT Secretary, World Tribology Council, Materials for

Energy (EMIRI), ECP4 (Plastic and composites), CAPTECH (Materials for

defense), JTI (Biomass industries).

• A team of 20 persons with accumulated experience during several years in

tribological subjects with 5 PHD in the team (8 PHD in September),

• Complete laboratory with 20 tribometers, 3 potentiostat. Wide variety of

tribological problems can be dealed.

• Direct Colaboration with other Units from IK4-TEKNIKER highly related to

tribology:

• Maintenance

• Failure diagnostics

• Oil analysis

• Mechanical design, sensors, robotics

• Physics and Chemistry of surfaces

• Láser, micro and nano machining


Tribological Solutions available at IK4-TEKNIKER

• PVD coatings

• PEO coatings

• Laser surface texturing

• Laser cladding (laser melting deposition)

• Sol gel

50X 100X 200X


NEED: To evaluate material capability, tribochemistry, tribodesorption and tribomechanisms under

vacuum or ultrahigh vacuum conditions, controlling their volatility (total mass loss, collected volatile

material, water regained).

WHY: Titanium is a light component, widely used in aerospace application because of their good

mechanical properties, but has bad tribological properties.

SOLUTIONS: Lubricants or Ionic liquids with low volatility to work under vacuum and ultrahigh

vacuum.

HOW: Developing a protective film or tribofilm by chemical reactions surface/lubricant in the sliding

contact. Tribochemical reaction.

CAracterization:

Tribochemistry

Tribodesorption analysis

Tribomechanism

- Friction and wear at Ultra High Vacuum

CA3UHV-CATRI

Home Made New testing equipments Vacuum and Ultrahigh Vacuum

© IK4-TEKNIKER Machines

DEMETRA

Total Mass loss

Collected volatil

condensable

material

Water regained

ASTM E595

Tribology in Agressive Environment: Vacuum


Triborectivity

Studies: Ionic liquids (halogen, or

Halogen free) to lubricate Ti, Steel

Actions: Testing friction, Wear,

Corrosion, tribocorrosion, vacuum

Interest:

• Low friction

• Wear and corrosion resistance

• Tribocorrosion resistance

• Tribodesorption control

• Tribolayer formation

Ionic liquids as Lubricants in atmospheric and vacuum conditions

High performance fluids and additives

XTRIBOLOGY-COMET

Tribology of Ionic Liquids

a b c


Novel Maintenance Concepts Mechanical & Chemical Wear + their Synergy

Coatings: PVD (arc, sputtering hippims), PEO

Solutions: Surface texturing, Roll to Roll, paints,

roughness

Actions:

•Corrosion, Wear, tribocorrosion resistance

Application: Biomedical, turbines, off shore, marine

Use minimum chemomechanical wear

Tribocorrosion

Tribology in aggresive environment: Tribocorrosion

TiN/CrN

Nadia, Ralpe, EmaitekFoulXPel, Alella, Funcoat


In Off shore, Marine Environmentally friendly antifouling & anticorrosion solutions

Coating: Environmentally antifouling Coatings.

Solutions: Surface treatment (Roll to Roll, paints,

texturing) to reduce fuel consumption

Actions:

•Testing drag friction (reduce)

•Texturing (control cell adhesion)

•Corrosion, Wear (reduce)

•Antifouling properties (tribobioadhesion)

•Paint release ecotoxicity tests (minimize)

Results: Benchmarking Solutions

maintenance rules.

Environmentally friendly antifouling (Tribobioadhesion) & anticorrosion solutions

mcqHCaT 425.0

0,00E+00

1,00E-03

2,00E-03

3,00E-03

4,00E-03

5,00E-03

200 500 1000 1500

Dra

g F

ricti

on

Speed (rpm)

Drag friction

;)(

Re

aba

Bacteria ISO 11348 Alga growth OECD 201

ShipsMotrico Port

50X 100X 200X

Tribology in aggresive environment: Tribobiocorrosion

http://marineinsight.com/wp-content/uploads/2011/06/image3.jpg


Medical Applications: hip & Knee Prosthesis Antibacterial & tribocorrosion resistant solutions

Coatings: TiCN coatings & PEO Coatings

Antibacterial Solutions: Silver, Iodine,..

Actvities:

•Tribological & tribocorrosion tests

•Fretting tests

•Antimicrobial (control bacteria tribobioadhesion)

•Results: increase of durability of hip and knee

prosthesis, avoiding infection

PVD Coatings and PEO coatings

Tribology in aggresive environment: Tribobiocorrosion

Bacterial adhesion (friction phenomena)


Testing components efficiency

Studies: Light brakes, squeal-free

& high efficient clutches

Actions:Testing & modelling

Construction of testing benches.

Interest :

• High Durability

• Asbestos free pads

• Control dust emissions

• Resistance to fadding

• Constant high friction, high efficiency

• Noise reduction

Testing durability and squeal of Brakes & Clutches

Novel Product design, Manufacturing & Maintenance

Brakesqueal, Jolie, I-Sinter

Tribology of mechanical components: Brakes & Clutches

Clutch test vs Pin on Disc



Studies: geometrical errors (α, Fα, Fβ, Fp),

materials, coatings

Actions:Testing & modelling

Interest: Durability, noise reduction

Testing durability of gears

Sensors Signalscollected

Acelerómeters Vibration (X, Y, Z)

Transducer in the axis of the Wheeland in the axis of the pinion

Transmissionerror

Torque sensor at the axis entry and in the Wheel axis.

Power loss

Microphone Noise

Termocouple PT-100 Temperature

Drive motor Intensity

PittingMicropitting band Scuffing

Novel Product design, manufacturing & Maintenance

Tess, Optimize, Sunoil, Biogrease, Biomon

Tribology of mechanical components: Gears

Aerohums, Selena



Studies: Lead free materials, coatings

Actions:Testing materials, lubricants

Interest:

• Durability,

• noise reduction,

• Reduce contact temperature

• Reduction of environmental impact

Testing durability of Journal bearings.

Novel Product design, materials & Maintenance

BeLeadFree bearings, Ecobearings, GraphnologyCleanengine

Tribology of mechanical components: Journal Bearings

Journal Bearing Simulation

Thrust Washer Test Configuration

CuPb22Sn disc against 50CrV4 ring

0

20

40

60

80

100

1 301 601 901 1201 1501 1801 2101 2401 2701 3001 3301 3601 3901

Temperature (ºC)



Studies: materials, coatings


Modelling life with oil sensors

and vibrations

Interest:

• Durability, pitting, micropitting

• Vibration & noise reduction,

• Reduction of contact temperature

Testing durability of Rolling bearings.

Novel Product design, materials & Maintenance

Biomon, Eurobearing, Refine, Twin Control

Tribology of mechanical components: Rolling Bearings


High Temperature resistance Materials Increase durability

Type of failures:

• Thermal fatigue

• Mechanical fatigue

• Die soldering

• Abrasion, adhesion

• Stress corrosion

▪Results: Prediction of lifetime▪ Type moulds: HPDC, PIM

▪Current activites: Technological services, research

projects

Solutions to:

• predict lifetime of materials at high temperature

Prediction of lifetime of materials at high temperature

High temperature tribology: Moulds wear

Alepre


Light weight Materials Plasma Electroxidation Coatings for Al, Mg, Ti

Need: Weight reduction.

Material: Al, Ti, Mg. Coating: PEO

Actions:

•Samples preparation and coating application

•Coating in components.

•Corrosion resistance

•Tribological tests cylinder liner piston rings

•Tribocorrosion tests.

Results: Benchmarking tribological solutions.

Use transport: for enhancing properties of light alloys

Substitution of cast iron by Aluminio +PEO

Al2O3

NADIA, NANOMAGCLEANENGINE, EREBIO

High temperature tribology: Engine Components

AUMORE, MOTORGARBI, REMTRAL, EQUIMOTOR


Pistons Coatings, biolubricants, biofuels

Need: Reduction of scuffing.

Coatings: DLC, HVOF, CrN and TiN

.Actions:

•Design of testing configuration

•Lubrication oil, oil/fuel (2 stroke engines).

•Corrosion resistance

•Tribological tests cylinder liner piston rings

•Tribological tests piston skirt/cylinder liner

•Tribocorrosion tests.

Results: Benchmarking tribological solutions.

Use: reduction of emisions, Lubricants compatible

with biofuels

Clean engines (low emission, biofuels, biolubricants)

NADIA, NANOMAGCLEANENGINE, EREBIO

High temperature tribology: Engine Components

AUMORE, MOTORGARBI, REMTRAL, EQUIMOTOR



Studies: materials, coatings, texturing


Modelling life with oil sensors

and vibrations

Interest:

• Durability, los friction, leakage

• Vibration & noise reduction,

• Reduction of contact temperature

• ISO 7986: 1997.

Testing durability of Seals and Elastomers


Stokes, Isselub,

Tribology of soft materials: Seals and elastomers

Load

Plunger

holders

Rubber

sample

Oil bath

Movement direction

Rod

50X 100X 200X

3D Flex


Testing safety


Actions:Testing materials, coatings

Stick Slip, slippery, in water, oil,

Antimicrobial, cleaning agents

Interest:

• Durability

• Noise, stick slip

• Slippery, Comfort

• Antimicrobial

Testing durability of Floorings.


SafeSlip

Tribology of soft materials: Antislip Floorings

Without biocide With biocide


Testing Comfort, safety


Actions:Testing materials, coatings

Tactile, stick slip, tearing, strength,

Antimicrobial, cleaning agents

Interest:

• Durability

• Tactile, stick slip

• Comfort

• Antimicrobial

Testing durability and comfort of Textiles

Novel Product materials design & quality

2B Funtex

Tribology of soft materials: Textiles

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0 50 100 150 200 250 300 350 400 450

Fric

. Co

ef.

(µ

)

Time (s)

Comparative Dry-Wet Conditions

Cotton 100% Dry

Polyester 100% Dry

50%Cotton-50%Polyester Dry

Cotton 100% Wet

Polyester 100% Wet

50%Cotton-50%Polyester Wet

0

5

10

15

20

25

30

35

0 20 40 60 80 100 120 140 160 180

Load

(N

)

Extension (mm)

Tear Tests

100% Cotton across warp

100% Cotton across weft

Polyester 100% across warp

Polyester 100% across weft

50% Cotton + 50% Polyester across warp

50% Cotton + 50% Polyester across weft

Emaitek

http://agrega.educacion.es/galeriaimg/3e/es_20071227_1_5001561/es_20071227_1_5001561_captured.jpg

http://edwinpireh.com/wp-content/uploads/2013/02/Warp_and_weft-web.jpg


Testing eco-efficiency

Studies: materials, coatings, lubricants

Actions: Testing efficiency, torque,

Lubricant properties, ecotoxicity,

Biodegradability, lifecycle assessment

Interest:

• Increase efficiency

• Reduce torque

• Reduce of working temperature

• Minimal quantity of fluid

• Lifecycle environmental assessment

• Low ecotoxicity (OECD 201, 202)

• Biodegradability after use (OECD 301F)

Testing efficiency of sunflower based cutting fluids

Improvement of process (tool, Lubrication, ecology)

Tribolubrication: Cutting and forming applications

ROTATIONAL DRAWING

0

0,5

1

1,5

2

2,5

3

3,5

4

4,5

5

0,00 0,05 0,10 0,15 0,20 0,25

TIME (sec)

TO

RQ

UE

(N

m)

100 98

0

20

40

60

80

100

120

Mineral (REF) VOSOLUB

% R

ela

tiv

e e

ffic

ien

cy

Tapping Cutting (Titanium)

FlankWear


Ecotribological solutions

Studies: HOSO base oils

and glycol free fire resistance

hydraulic oils

Actions: Testing friction, Wear,

extreme pressure, biodegradability,

ecotoxicity

Interest:

• Durability

• Low friction

• High extreme pressure

• Biodegradable after use

• Non ecotoxic

Testing durability in hydraulic fluids (aerogenerators, agricultural machinery, hydraulic equipments)

Novel ecofriendly lubricants design & maintenance

Biovesin

Tribology of ecolubricants: Bearings and Gears

Extreme pressure test results 1

Lubricant Seizure load

RAGH 126

BIOGIR-06 160

2

Extreme pressureFire resistant

Biodegradable


How Tribology will help new materials to survive in different environments and systems

Friction related Phenomena

Tribology, Tribolubrication, Tribocorrosion, Tribochemistry, Tribodesorption, Triboreactivity, Tribolayer,

Tribomechanisms, Biotribology, Tribobioadhesion, tribobiocorrosion (tribobioadhesion+tribocorrosion)

Damage Mechanisms (chemical & mechanical Wear) and friction consequences

Pitting, Micropitting, Scuffing, fretting, fading, stick-slip, die soldering, abrasión, adhesion, corrosion,

stress corrosion, thermal fatigue, drag friction, efficiency, noise, vibration, squeal, slippery, tactility,..

comfort

1. A huge range of testing equipments are available to simulate different environments

2. The knowledge about the working conditions and reproduction of failure mechanism at laboratory

will make possible to reproduce a wider number of tribological systems.

3. It is necessary to make a step forward towards modelling the extrapolation of the laboratory testing

to the real system and the generation of new standards.

4. Tribology is the tool to implement low carbon footprint materials into energy and resource efficient

real systems

CONCLUSIONS


• Thanks for your interest

• Organization of EuroNanoForum and EU Commission

• Financing Agencies at EU, National and Regional level

• Collaborators in the EU, National and Industrial Projects

• Colleagues from IK4-TEKNIKER that participated in the results

ACKNOWLEDGEMENTS

The Importance of Tribology in Demanding Industrial...

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