The generation of wear surfaces

Abrasive wear is likely to occur whenever a hard asperity or a trapped hard particle is dragged across a softer surface, and it has been estimated that this form of wear contributes to as many as half of the wear problems that are met in industry. Such damaging hard particles may be external contaminants, products of corrosion or even the debris from previous wear events. During the life of a component, damage caused by individual asperity or particle interactions builds up and, at each stage of its life, the worn surface is the result of many such superimposed wear events. The practical, quantitative prediction of wear rates depends on having both a satisfactory understanding of individual interactions and a suitable procedure for combining these when subsequent contacts are made on a surface whose topography and material properties may have been much changed Irom their initial states. The paper includes some details of an analytical model for the interaction of a representative asperity and the worn surface which can both predict the frictional force and the balance between ploughing, when material is displaced but not lost from the surface, and micromachining or cutting, when actual detachment occurs. Experiments tö !rvvéSuQ8Î8 the validity of the model have been carried out on a novel wear rig which provides very precise control over the position of the asperity and the counterface. This facility, together with that of on-board profilometry, means that it is possible to carry out wear experiments on areas of the surface whose previous deformation history is well known; in this way it is possible to follow the development of a worn surface in a controlled manner as the damage from individual wear events accumulates. Experimental data on the development of such a surface, produced by repeated parallel abrasion, are compared with the predictions of the model. © 1992 IOP Publishing Ltd.

Stepped gate polysilicon thin film transistor for large area power applications

For the first time, we report a new poly-Si stepped gate Thin Film Transistor (SG TFT) on glass. The Density of States extracted from measured I-V characteristics has been used to evaluate the device performance with a two dimensional device simulator. The results show that the three-terminal SG TFT device has a switching speed comparable to a low voltage structure and the high on-current capability of a metal field plate (MFP) TFT and the potential for comparable breakdown characteristics.

The contact of rough surfaces carrying pressure sensitive boundary layers

When two rough surfaces are loaded together it is well known that the area of true contact is very much smaller then the geometric area and that, consequently, local contact pressures are very much greater than the nominal value. If the asperities on each surface can be thought of as possessing smooth summits and each of the solids is elastically isotropic then the pressure distribution will consist of a series of small, but severe, Hertzian patches. However, if one of both of the surfaces in question is protected by a boundary layer then both the number and dimensions of these patches, and the form of the pressure distribution within them, will be modified. Recent experimental evidence from studies using both Atomic Force Microscopy and micro-tribometry suggests that boundary films produced by the action of commercial anti-wear additives, such as ZDTP, exhibit mechanical properties, which are affected by local values of pressure. These changes bring about further modifications to local conditions. These effects have been explored in a numerical model of rough surface contact and the implications for the mechanisms of surface distress and wear are discussed. © 2000 Elsevier Science B.V. All rights reserved.

Materials science: The ultrasmoothness of diamond-like carbon surfaces

The ultrasmoothness of diamond-like carbon coatings is explained by an atomistic/continuum multiscale model. At the atomic scale, carbon ion impacts induce downhill currents in the top layer of a growing film. At the continuum scale, these currents cause a rapid smoothing of initially rough substrates by erosion of hills into neighboring hollows. The predicted surface evolution is in excellent agreement with atomic force microscopy measurements. This mechanism is general, as shown by similar simulations for amorphous silicon. It explains the recently reported smoothing of multilayers and amorphous transition metal oxide films and underlines the general importance of impact-induced downhill currents for ion deposition, polishing, and nanopattering.

Reconstruction of surfaces of revolution from single uncalibrated views

This paper addresses the problem of recovering the 3D shape of a surface of revolution from a single uncalibrated perspective view. The algorithm introduced here makes use of the invariant properties of a surface of revolution and its silhouette to locate the image of the revolution axis, and to calibrate the focal length of the camera. The image is then normalized and rectified such that the resulting silhouette exhibits bilateral symmetry. Such a rectification leads to a simpler differential analysis of the silhouette, and yields a simple equation for depth recovery. It is shown that under a general camera configuration, there will be a 2-parameter family of solutions for the reconstruction. The first parameter corresponds to an unknown scale, whereas the second one corresponds to an unknown attitude of the object. By identifying the image of a latitude circle, the ambiguity due to the unknown attitude can be resolved. Experimental results on real images are presented, which demonstrate the quality of the reconstruction. © 2004 Elsevier B.V. All rights reserved.

Friction of sliding surfaces carrying adsorbed lubricant layers

In concentrated contacts the behaviour of lubricants is much modified by the high local pressures: changes can arise both from molecular ordering within the very thin film lubricant layers present at the interface as well as from the deposition on the component surfaces of more solid-like polymeric boundary layers. These 'third bodies' separating the solid surfaces may have rheological or mechanical properties very different from those observed in the bulk. Classical elasto-hydrodynamic theory considers the entrapped lubricant to exhibit a piezo-viscous behaviour while the conventional picture of more solid boundary lubricant layers views their shear strength r as being linearly dependent on local pressure p, so that T = TO + ap where TO and a are constants. If TO is relatively small, then the coefficient of friction \i = T Ip ~ a and so Amonton's laws are recovered. However, the properties of adsorbed or deposited surface films, or indeed other third bodies such as debris layers, may be more complex than this. A preliminary study has looked quantitatively at the influence of the pressure dependence of the shear strength of any surface layer on the overall friction coefficient of a contact which is made up of an array of asperities whose height varies in a Gaussian manner. Individual contact points may be elastic or plastic. The analysis results in plots of coefficient of friction versus the service or load parameter PIH&NRa where P is the nominal pressure on the contact, HS the hardness of the deforming surface, N the asperity density, R the mean radius of curvature of the asperities, and a is the standard deviation of their height distribution. In principle, any variation oft withp can be incorporated into the model; however, in this initial study we have used data on colloidal suspensions from the group at the Ecole Centrale de Lyon as well as examining the effect of functional relationships of somewhat greater complexity than a simple linear form. Results of the analysis indicate that variations in fj. are possible as the load is varied which depend on the statistical spread of behaviour at individual asperity contacts. The value of this analysis is that it attempts to combine the behaviour of films on the molecular scale with the topography of real engineering surfaces and so give an indication of the effects at the full-size or macro-scale that can be achieved by chemical or molecular surface engineering.

Movement of deposited water on turbomachinery rotor blade surfaces

A theoretical approach for calculating the movement of liquid water following deposition onto a turbomachine rotor blade is described. Such a situation can occur during operation of an aero-engine in rain. The equation of motion of the deposited water is developed on an arbitrarily oriented plane triangular surface facet. By dividing the blade surface into a large number of facets and calculating the water trajectory over each one crossed in turn, the overall trajectory can be constructed. Apart from the centrifugal and Coriolis inertia effects, the forces acting on the water arise from the blade surface friction, and the aerodynamic shear and pressure gradient. Non- dimensionalisation of the equations of motion provides considerable insight and a detailed study of water flow on a flat rotating plate set at different stagger angles demonstrates the paramount importance of blade surface friction. The extreme cases of low and high blade friction are examined and it is concluded that the latter (which allows considerable mathematical generalisation) is the most likely in practice. It is also shown that the aerodynamic shear force, but not the pressure force, may influence the water motion. Calculations of water movement on a low-speed compressor blade and the fan blade of a high bypass ratio aero-engine suggest that in low rotational speed situations most of the deposited water is centrifuged rapidly to the blade tip region. Copyright © 2006 by ASME.

Ink-jet printing for patterning engineering surfaces

This work explored the use of industrial drop-on-demand inkjet printing for masking steel surfaces on engineering components, followed by chemical etching, to produce patterned surfaces. A solvent-based ink was printed on to mild steel samples and the influences of substrate topography and substrate temperature were investigated. Contact angle measurements were used to assess wettability. Regular patterns of circular spots (∼60 /on diameter) and more complex mask patterns were printed. Variation of the substrate temperature had negligible effect on the final size of the printed drops or on the resolution achieved. Colored optical interference fringes were observed on the dried ink deposits and correlated with film thickness measurements by whitelight interferometry.

Characterisation and simulation of asphalt road surfaces

Accurate simulation of rolling-tyre vibrations, and the associated noise, requires knowledge of road-surface topology. Full scans of the surface types in common use are, however, not widely available, and are likely to remain so. Ways of producing simulated surfaces from incomplete starting information are thus needed. In this paper, a simulation methodology based solely on line measurements is developed, and validated against a full two-dimensional height map of a real asphalt surface. First the tribological characteristics-asperity height, curvature and nearest-neighbour distributions-of the real surface are analysed. It is then shown that a standard simulation technique, which matches the (isotropic) spectrum and the probability distribution of the height measurements, is unable to reproduce these characteristics satisfactorily. A modification, whereby the inherent granularity of the surface is enforced at the initialisation stage, is introduced, and found to produce simulations whose tribological characteristics are in excellent agreement with the measurements. This method will thus make high-fidelity tyre-vibration calculations feasible for researchers with access to line-scan data only. In addition, the approach to surface tribological characterisation set out here provides a template for efficient cataloguing of road textures, as long as the resulting information can subsequently be used to produce sample realisations. A third simulation algorithm, which successfully addresses this requirement, is therefore also presented. © 2011 Elsevier B.V.