Mechanical face seals, MFS, are important machine components in the heavyduty-vehicle industry which generate a high frictional power loss. In order to lower these losses an investigation has to be performed on the frictional behavior of the MFS. A physical test rig allows an evaluation of existing seals and new concepts to compare their performances. Prior to this project, a test rig for MFS had been partially designed and manufactured by a group of students within a design project at KTH. This report presents the continuation of this work. A solid background study was performed in which the best testing equipment and theoretical models in the literature to characterize MFS were reviewed. The design and manufacturing of the test rig prototype has been completed and most importantly, it has been validated, achieving an acceptable assessment of repeatability. Tests have been planned and executed to assess the repeatability of the test rig and to study the effect of different parameters: speed, preload, eccentricity and angular misalignment. A theoretical loss model was performed which gave discrepant results for studies with mixed lubrication, making a comparison with the experiments impracticable. Further work has to be done to evaluate the applicability of the proposed model. In addition, a valuable Matlab tool has been developed and packaged to facilitate processing data of the test rig for future users. / Mekaniska glidringstätningar är viktiga maskinkomponenter inom tung fordonsindustri, men de orsakar höga friktionsförluster. För att sänka dessa förluster behöver först en undersökning utföras för att få förståelse för friktionsbeteendet hos de mekaniska glidringstätningarna. En fysisk testrigg gör det möjligt att utvärdera befintliga tätningar och jämföra deras prestanda med nya koncept. Denna rapport är en uppföljning på ett koncept av en testrigg för mekaniska för glidringstätningar som en grupp studenter på KTH tidigare tagit fram. Innan detta projekt hade en testrigg för konceptet delvis utformats och tillverkats. Fortsättningen av detta arbete innebar att en heltäckande bakgrundsundersökning utfördes samt även en granskning av teoretiska modeller för att karakterisera tätningarna. Konstruktion och tillverkning av den tidigare testriggen slutfördes. Dessutom validerades testriggen vilket visade att dess repeterbarhet var accepterbar. Tester planerades och utfördes för att studera effekten av följande parametrar: hastighet, kast, excentricitet och snedställning. En teoretisk förlustmodell utvecklades men visade sig ge avvikande resultat för blandsmörjning vilket gjorde jämförelser med experimenten ogenomförbara. Ytterligare arbete bör göras för att utvärdera tillämpligheten av den framtagna modellen. Utöver detta har även ett användargränssnitt i Matlab utvecklats och paketerats för att underlätta för framtida användare att bearbeta data från testriggen.

The current requirements in automotive lubrication impose complex formulation. Among all the additives present in oil, the presence of molybdenum dithiocarbamate and zinc dithiophosphate, both tribological additives containing sulfur and phosphorous is found. For environmental reasons, it is important to reduce or eliminate the presence of these two elements contained in oil. Organic molecules based on carbon, oxygen and hydrogen seems to be good candidate. The lubrication mechanism of fatty acids (e.g. stearic, oleic and linoleic acids) is revisited with a new approach combining experimental and computational chemistry studies. First, the adsorption mechanisms of fatty acids on iron-based surfaces are investigated by Ultra-Accelerated Quantum Chemistry Molecular Dynamics simulations. The adsorption of fatty acids on iron oxide surface occurred through the acid group. Depending on the nature of the substrate, on the density of the film and on the tilt angle between the molecule and the surface, different adsorption mechanisms (physisorption and chemisorption) can occur. Stearic acid molecules form a close-packed and well-arranged monolayer whereas unsaturation acids cannot because of steric effects induced by double carbon-carbon bonds. The friction process favors the formation of carboxylate function. Results are confirmed by surface analysis (XPS and PM-IRRAS). Tribological properties of pure fatty acids, blended in PAO 4 and mixture of saturated/unsaturated acids are studied by MD simulations and tribotests. Low friction coefficient with no visible wear is reported for pure stearic acid and single stearic acid blended in PAO 4 at 1%w at high temperature. This lubricating behavior is inhibited in the presence of unsaturated acids, especially at 150 °C. MD simulation results show a faster diffusion toward the surface for unsaturated fatty acids than for stearic acid at all studied temperature.

Le moteur à combustion, utilisé dans l’automobile est en perpétuelle évolution pour des raisons économiques et écologiques. Pour parvenir à de faibles consommations de carburant et émissions polluantes, l’un des axes étudiés est la réduction des pertes mécaniques par frottement du moteur qui constituent 15 à 20% de la consommation totale d’énergie du moteur. 50% de ces frottements proviennent des contacts Segment-Piston- Chemise et de la liaison Maneton-Bielle-Coussinet. De ce fait la compréhension de la tribologie de ce contact, l’optimisation de la lubrification et le vieillissement des lubrifiants deviennent primordiaux. L’objectif de cette thèse est d’étudier les mécanismes de lubrification de ces contacts segment/chemise et maneton/coussinet, et en particulier de comprendre l’influence du couplage additif, surface et matériau dans les différentes régimes de lubrification. Il s’agira de répondre à la question : comment maîtriser le frottement et l’usure en contrôlant la chimie du lubrifiant, la topographie et le matériau ? La démarche expérimentale choisie s’appuie sur l’analyse du comportement tribologique de deux additifs modificateurs de frottement sans cendres d’une part, puis sur l’impact du matériau et enfin sur l’influence de la topographie d’autre part. L’analyse de la cinétique d’évolution du coefficient de frottement et des traces d’usure en régime limite ont notamment permis d’identifier les mécanismes de réduction de frottement induits par les deux modificateurs étudiés. / The combustion engine used in automotive industry is constantly changing for economic and ecological reasons. To achieve low fuel consumption and pollutants emissions, one of research axes studied is the reduction of the mechanical friction loss of the motor which constitute 15-20 % of the total energy consumption of the engine. 50% of these come from friction contacts cylinder /piston rings and conrod bearing. Thereby understanding of tribology of the contact, optimizing lubrication and lubricants aging become paramount. The objective of this thesis is to study the mechanisms of lubrication of these contact (piston ring/cylinder and conrod bearing), and in particular to understand the influence of the additive coupling surface and material in the different lubrication regimes. This will answer the question : how to control the friction and wear by controlling the chemistry of the lubricant, the topography and the material ? The experimental approach chosen is based on the analysis of the tribological behavior of two friction modifiers additives ashless at first time, and on the impact of material and finally the influence of topography on the second time. XPS Analysis of the evolution of the coefficient of friction and wear track under boundary regime have enabled to identify mechanisms to reduce friction induced by the two modifiers studied.

Les exigences actuelles en terme de lubrification automobile imposent des formulations extrêmement complexes. Parmi tous les additifs présents dans l’huile, on peut noter le dithiocarbamate de molybdène et le dithiophosphate de zinc, additifs à action tribologique à base de soufre et de phosphore. Pour des raisons environnementales, il est important de diminuer voir d’éliminer la présence de ces deux éléments dans les huiles. Les molécules organiques à base de carbone, oxygène et hydrogène semblent être de bons candidats. Le mécanisme de lubrification des acides gras (acides stéarique, oléique et linoléique) est revisité par une approche visant à combiner l’étude expérimentale et la modélisation moléculaire. Tout d’abord, les mécanismes d’adsorption des acides gras sur des surfaces à base de fer sont étudiés par couplage Chimie Quantique et Dynamique Moléculaire (UA-QCMD). L’adsorption des acides gras sur des surfaces à base de fer se fait par la fonction acide. Selon la nature du substrat, la densité du film et l’angle d’inclinaison de la molécule par rapport à la surface, différents mécanismes d’adsorption peuvent avoir lieu (physisorption et chimisorption). Les molécules d’acide stéarique forment une monocouche compacte et bien arrangée alors que les molécules insaturées en sont incapables à cause d’effets stériques induits par les doubles liaisons carbone-carbone. Le frottement favorise la formation de la fonction carboxylate. Ces résultats sont confirmés par des analyses de surface (XPS et PM-IRRAS). Les propriétés tribologiques des acides gras purs, dans la PAO 4 et en mélange dans la PAO 4 sont étudiées par simulation MD et par des tribotests. Un faible frottement et une absence d’usure visible ont été observés pour l’acide stéarique pur et dissous à 1%m dans la PAO 4 à haute température. La présence de molécules insaturées inhibe les propriétés réductrices de frottement de l’acide stéarique, en particulier à 150 °C. Ceci est expliqué par la diffusion des acides gras insaturés bien supérieure à celle de l’acide stéarique dans la PAO 4 à toutes les températures étudiées. / The current requirements in automotive lubrication impose complex formulation. Among all the additives present in oil, the presence of molybdenum dithiocarbamate and zinc dithiophosphate, both tribological additives containing sulfur and phosphorous is found. For environmental reasons, it is important to reduce or eliminate the presence of these two elements contained in oil. Organic molecules based on carbon, oxygen and hydrogen seems to be good candidate. The lubrication mechanism of fatty acids (e.g. stearic, oleic and linoleic acids) is revisited with a new approach combining experimental and computational chemistry studies. First, the adsorption mechanisms of fatty acids on iron-based surfaces are investigated by Ultra-Accelerated Quantum Chemistry Molecular Dynamics simulations. The adsorption of fatty acids on iron oxide surface occurred through the acid group. Depending on the nature of the substrate, on the density of the film and on the tilt angle between the molecule and the surface, different adsorption mechanisms (physisorption and chemisorption) can occur. Stearic acid molecules form a close-packed and well-arranged monolayer whereas unsaturation acids cannot because of steric effects induced by double carbon-carbon bonds. The friction process favors the formation of carboxylate function. Results are confirmed by surface analysis (XPS and PM-IRRAS). Tribological properties of pure fatty acids, blended in PAO 4 and mixture of saturated/unsaturated acids are studied by MD simulations and tribotests. Low friction coefficient with no visible wear is reported for pure stearic acid and single stearic acid blended in PAO 4 at 1%w at high temperature. This lubricating behavior is inhibited in the presence of unsaturated acids, especially at 150 °C. MD simulation results show a faster diffusion toward the surface for unsaturated fatty acids than for stearic acid at all studied temperature.