Models and methods for the direct simulation of rough and micropatterned surfaces

Friction in hydrodynamic bearings are a major source of losses in car engines ([69]). The extreme loading conditions in those bearings lead to contact between the matching surfaces. In such conditions not only the overall geometry of the bearing is relevant, but also the small-scale topography of the surface determines the bearing performance. The possibility of shaping the surface of lubricated bearings down to the micrometer ([57]) opened the question of whether friction can be reduced by mean of micro-textures, with mixed results. This work focuses in the development of efficient numerical methods to solve thin film (lubrication) problems down to the roughness scale of measured surfaces. Due to the high velocities and the convergent-divergent geometries of hydrodynamic bearings, cavitation takes place. To treat cavitation in the lubrication problem the Elrod- Adams model is used, a mass-conserving model which has proven in careful numerical ([12]) and experimental ([119]) tests to be essential to obtain physically meaningful results. Another relevant aspect of the modeling is that the bearing inertial effects are considered, which is necessary to correctly simulate moving textures. As an application, the effects of micro-texturing the moving surface of the bearing were studied. Realistic values are assumed for the physical parameters defining the problems. Extensive fundamental studies were carried out in the hydrodynamic lubrication regime. Mesh-converged simulations considering the topography of real measured surfaces were also run, and the validity of the lubrication approximation was assessed for such rough surfaces.

Influência do acabamento superficial no desempenho de lubrificantes de motor novos e usados em automóveis abastecidos com E22 e E100.

Superfícies anisotrópicas lisas e rugosas foram usadas para avaliar o efeito da rugosidade e da direção de acabamento na formação de MoS2 a partir de MoDTC em ensaios tribologicos lubrificados com óleos de motor completamente formulados. Igualmente foi avaliada a resposta de atrito de lubrificantes de motor usados em carros de passageiros e em testes de dinamômetro abastecidos com etanol (E100) e gasolina (E22). Encontrou-se que tanto a direção de acabamento quanto a rugosidade foram fundamentais na reação MoDTC - MoS2. A direção de acabamento influenciou na medida que carregamentos tangenciais geram respostas diferentes nos ensaios quando são realizados paralelos e perpendiculares às linhas de acabamento, dado que para os últimos apresenta-se maior deformação plástica das asperezas, o qual favorece a obtenção de superfícies livres de óxidos, que tem sido indicada como uma condição necessário para que aconteça a reação MoDTC - MoS2. Por esta razão os valores de coeficiente de atrito próprios da formação de MoS2 foram obtidos somente nas superfícies rugosas ensaiadas perpendiculares às marcas de acabamento. Para superfícies com valores de índice de plasticidade superiores a 1 e nos quais não são formados filmes com boas capacidades redutoras de atrito, como é o caso de ensaios realizados com óleos base (livres de aditivos), o coeficiente de atrito não depende da rugosidade e da direção de acabamento. Nos ensaios lubrificados com óleos usado, encontraram-se valores de coeficiente de atrito similares aos obtidos nas condições de lubrificação com óleo livres de aditivos, devido provavelmente à redução do MoDTC no lubrificante como tem sido identificado por diferentes autores. Quando foram comparados os óleos usados contaminados com etanol com os óleos usados contaminados com gasolina, encontrou-se maior oxidação nestes últimos. Mesmo que estas diferenças de oxidação dos óleos não significaram diferenças em termos de atrito, estas podem ser importantes na medida em que óleos mais oxidados podem favorecer o desgaste oxidativo.

The tribology of laminated magnetic recording heads

This thesis investigates the mechanisms that lead to pole tip recession (PTR) in laminated magnetic recording heads (also known as "sandwich heads"). These heads provide a platform for the utilisation of advanced soft magnetic thin films in practical recording heads suitable for high frequency helical scan tape recording systems. PTR results from a differential wear of the magnetic pole piece from the tape-bearing surface of the head. It results in a spacing loss of the playback or read signal of 54.6dB per recording wavelength separation of the poles from the tape. PTR depends on the material combination used in the head, on the tape type and the climate - temperature and relative humidity (r.h.). Five head materials were studied: two non-magnetic substrate materials- sintered multi granular CaTi03 and composite CaTi03/ZrTi04/Ti02 and three soft magnetic materials- amorphous CoNbZr, and nanocrystalline FeNbSiN and FeTaN. Single material dummy heads were constructed and their wear rates measured when cycling them in a Hi-8 camcorder against commercially available metal particulate (MP) and metal evaporated (ME) tapes in three different climates: 25°C/20%r.h., 25°C/80%r.h. and 40°C/80%r.h. X-ray photoelectron spectroscopy (XPS) was used to examine changes the head surface chemistry. Atomic force microscopy (AFM) was used to examine changes in head and tape surface topography. PTR versus cycling time of laminated heads of CaTi03/ZrTiO4/Ti02 and FeTaN construction was measured using AFM. The principal wear mechanism observed for all head materials was microabrasion caused by the mating body - the tape surface. The variation in wear rate with climate and tape type was due to a variation in severity in this mechanism, except for tape cycling at 40°C in which gross damage was observed to be occurring to the head surface. Two subsidiary wear mechanisms were found: third body scratching (all materials) and grain pullout (both ceramics and FeNbSiN). No chemical wear was observed, though tribochemical reactions were observed on the metal head surfaces. PTR was found to be caused by two mechanisms - the first differential microabrasion of the metal and substrate materials and which was characterised by a low (~10nm) equilibrium value. The second was by deep ploughing by third body debris particles, thought mainly to be grain pullout particles. This level of PTR caused by this mechanism was often more severe, and of a non-equilibrium nature. It was observed more for ME tape, especially at 40°C/80%r.h. and 25°c/20%r.h. Two other phenomena on the laminated head pole piece were observed and commented upon: staining and ripple texturing.

Modelling tribology of slider and disk in a computer hard drive system

Issues of wear and tribology are increasingly important in computer hard drives as slider flying heights are becoming lower and disk protective coatings thinner to minimise spacing loss and allow higher areal density. Friction, stiction and wear between the slider and disk in a hard drive were studied using Accelerated Friction Test (AFT) apparatus. Contact Start Stop (CSS) and constant speed drag tests were performed using commercial rigid disks and two different air bearing slider types. Friction and stiction were captured during testing by a set of strain gauges. System parameters were varied to investigate their effect on tribology at the head/disk interface. Chosen parameters were disk spinning velocity, slider fly height, temperature, humidity and intercycle pause. The effect of different disk texturing methods was also studied. Models were proposed to explain the influence of these parameters on tribology. Atomic Force Microscopy (AFM) and Scanning Electron Microscopy (SEM) were used to study head and disk topography at various test stages and to provide physical parameters to verify the models. X-ray Photoelectron Spectroscopy (XPS) was employed to identify surface composition and determine if any chemical changes had occurred as a result of testing. The parameters most likely to influence the interface were identified for both CSS and drag testing. Neural Network modelling was used to substantiate results. Topographical AFM scans of disk and slider were exported numerically to file and explored extensively. Techniques were developed which improved line and area analysis. A method for detecting surface contacts was also deduced, results supported and explained observed AFT behaviour. Finally surfaces were computer generated to simulate real disk scans, this allowed contact analysis of many types of surface to be performed. Conclusions were drawn about what disk characteristics most affected contacts and hence friction, stiction and wear.

Avaliação tribológica de novas modificações superficiais para cilindros de laminação a frio

The present work analyzed the tribological behavior of coatings/surface modifications traditionally used in cold rolling mill rolls and new coatings/surface modificationswith potential to replace the carcinogenic hard chrome. The study started with identification of wear mechanisms occurring in real coldrollingmill rolls. Due the high cost and dimensions of the rolls, thereplication technique was used. Replicas were obtained from 4 different rolling millBrazilian companies before and after a normal rolling campaign. Initial sliding tests were conducted using spherical and cylindrical counter bodies in order to verifywhichtribological conditions allowed to reproduce the wear mechanisms found in the replicas. These tests indicated the use of reciprocating sliding tests with cylindrical counter bodies (line contact), normal load of 100 N, and test times of and 1 h and 5 h. Different surface modifications were carried out on samples produced from a fragment of a rolling mill roll. The specimens were heat treated and ground on both sides. After, some specimens were surface textured by electrical discharge texturing (EDT). For both groups (ground and EDT), subsequent treatments of chromium plating, electroless NiP coating and plasma nitriding were carried out. The results of the reciprocating tests showed that specimens with electroless NiP coating presented the lowest friction coefficients, while plasma nitrided specimens showed the highest. In general, previous surface texturing before the coating/surface modification increased the wear of the counter bodies. Oneexceptionwas for EDT with subsequent electroless NiP coating, which presented the lowest counter bodies wear rate. The samples withelectroless NiP coating promoted a tribolayer consisting of Nickel, Phosphorus and Oxygen on both the specimens andthecounter bodies, which was apparently responsible for the reduction of friction coefficient and wear rate. The increase of the test time reduced the wear rate of the samples, apparently due the stability of the tribolayers formed, except for the nitrided samples. For the textured specimens, NiP coating showed the best performance in maintaining the surface topography of the specimens after the sliding tests.

Characterization of Copper Covetic Bulk and Films: Copper with High Carbon Content

Incorporation of carbon nanostructures in metals is desirable to combine the strongly bonded electrons in the metal and the free electrons in carbon nanostructures that give rise to high ampacity and high conductivity, respectively. Carbon in copper has the potential to impact industries such as: building construction, power generation and transmission, and microelectronics. This thesis focuses on the structure and properties of bulk and thin films of a new material, Cu covetic, that contains carbon in concentrations up to 16 at.%. X-ray photoelectron spectroscopy (XPS) shows C 1s peak with both sp2 and sp3 bonded C measuring up to 3.5 wt.% (16 at.%). High resolution transmission electron microscopy and electron diffraction of bulk covetic samples show a modulated structure of ≈ 1.6 nm along several crystallographic directions in regions that have high C content suggesting that the carbon incorporates into the copper lattice forming a network. Electron energy loss spectra (EELS) from covetics reveal that the level of graphitization from the source material, activated carbon, is maintained in the covetic structure. Bulk Cu covetics have a slight increase in the lattice constant, as well as <111> texturing, or possibly a different structure, compared to pure Cu. Density functional theory calculations predict bonding between C and Cu at the edges and defects of graphene sheets. The electrical resistivity of bulk covetics first increases and then decreases with increasing C content. Cu covetic films were deposited using e-beam and pulsed laser deposition (PLD) at different temperatures. No copper oxide or any allotropes of carbon are present in the films. The e-beam films show enhanced electrical and optical properties when compared to pure Cu films of the same thickness even though no carbon was detected by XPS or EELS. They also have slightly higher ampacity than Cu metal films. EELS analysis of the C-K-edge in the PLD films indicate that graphitic carbon is transferred from the bulk into the films with uniform carbon distribution. PLD films exhibit flatter and higher transmittance curves and sheet resistance two orders of magnitude lower than e-beam films leading to a high figure of merit as transparent conductors.