There are two main goals of this thesis. Firstly, to improve and develop an existing hot weartester at Karlstad University so that it may test more samples of different sizes. Secondly, totest previously impossible samples and investigate their tribological properties and measurethe coefficient of friction with high reproducibility. The development work on the tribometer wasdone by a prestudy including; Investigating the hot wear tester, idea generation in CAD andcollecting information from the creator and prior users of it. After a few rounds of conceptgeneration and discussion with the supervisor and workshop staff, a new sample holder withdifferent sample adapters was created. Five tests of four different materials were conductedand their friction was measured. The new sample holder was able to solve the mainconcerns with the old design and showed great promise in producing reproducible results,better than any previous versions. The friction of the different TiAlN samples, at roomtemperature, seemed to indicate that there is a certain amount of Al% that maximizes frictionand that there is no simple linear relationship between Al% and coefficient of friction. Finallyit can be concluded that the initial goals of the thesis have been met, and that a newscientific instrument has been created to aid in the further understanding of tribology. / Det finns två huvudsakliga mål med detta examensarbete. För det första, att förbättra ochutveckla en existerande varmnötare på Karlstad Universitet så att den kan testa fler proverav olika storlekar. För det andra, att testa tidigare omöjliga prov och undersöka derastribologiska egenskaper och mäta friktionskoefficienten med hög reproducerbarhet.Utvecklingsarbetet av tribometern skedde via en förstudie som innehöll följande:Undersökning av varmnötaren, idégenerering i CAD och samling av information frånvarmnötarens skapare, samt tidigare användare. Efter några iterationer avkonceptgenerering och diskussioner med handledare och verkstadspersonal så skapadesen ny provhållare med flera olika adaptrar. Fem tester med fyra olika material utfördes ochderas friktion mättes. Den nya provhållaren löste de huvudsakliga problemen med dengamla designen och påvisade goda förhoppningar angående att producera tester med högreproducerbarhet. Markant bättre än tidigare versioner. Friktionsmätningarna från de olikaTiAlN-proverna, vid rumstemperatur, indikerade att det finns en viss mängd Al% sommaximerar friktionen och att det inte finns något linjärt samband mellan Al% ochfriktionskoefficient. Slutligen kan det konstateras att de initiala målen för examensarbetet harblivit uppnådda, och att ett nytt vetenskapligt instrument har blivit skapat för att hjälpa utökaförståelse inom tribologi.

Achieving sustainable lubrication by using environmentally friendly formulated lubricants has became an essential component of the transition process from fossil-powered vehicles to electrified transportation. Mixtures, or aqueous solutions of molecules such as polyhydroxy alcohols, and glycols usually known as green lubricants make it possible to achieve low friction coefficients under different lubrication conditions, which constitutes a potential alternative to improve the tribological performance of moving parts in automotive systems, at the same time that the environmental requirements are satisfied. There is a need to improve the protection against mild-wear and micropitting offered by green-lubricants before consider using them in the transmission gear box of battery electric vehicles BEVs, where their low shear-stress resistance can potentially help to improve the vehicle efficiency. Therefore, this research work aims to gain understanding of the tribological behaviour of rolling-sliding elements under glycerol-based lubrication, with focus on assessing the influence of different glycerol-based lubricant formulations on the wear modes associated to rolling contact fatigue such as micropitting, and macropitting.  Micropitting tests were carried out by using a micropitting rig, with a roller on ring planetary configuration. The evolution of microcracks, and micropitting was studied for several glycerol-based lubricants at different slide-to-roll ratios (SRRs) 5-30%, and different load contact conditions 1.5-2.5 GPa. A comparison against a fully formulated transmission oil has been performed. A relationship between the surface damage morphology and the operating conditions has been established. The lubrication regimes of DLC coated contacts and uncoated contacts in presence of glycerol-based lubricants were investigated through the construction of 3D friction maps, and Stribeck curves in a wide range of rolling speeds, and SRR testing conditions. The capability of two different DLC coating systems to prevent micropitting onset due to rolling contact fatigue in presence of glycerol-based lubricants was studied: Cr/a-WC:H/a-C:H and a-C:Cr.  Under mixed-lubrication regime it was found that a reduction up to 51% of friction can be achieved by using glycerol-based lubricants compared to a commercial transmission oil. The initial low friction coefficients at low contact cycles was attributed to the low pressure-viscosity coefficient of the glycerol-based lubricants. Friction was even further reduced with the increasing contact cycles since glycerol aqueous solutions were found to promote mild-wear, causing a smoothing of the surface asperities and therefore an enhancement of the hydrodynamic effect due a higher lambda ratio (Λ), making possible to trigger superlubricity in the contact. Surface micro-cracking was found to decrease at low SRR values under glycerol-based lubrication contrasted to the contacts lubricated with a fully formulated transmission oil. Once microcracks were nucleated, micropitting progressed faster in the contacts lubricated with glycerol-based lubricants, while micropitting was null or significantly delayed in presence of transmission oil. With the increasing SRR surface microcracks density and micropitting was found to became higher. The reduction of microcracks density with a glycerol-glycol based lubricant was attributed to the adsorption of long glycol molecules on the steel surface that avoid the direct interaction between asperities. The faster micropitting progression was attributed to the presence of dissolved water in the contact. Thin DLC a-C:Cr coatings were shown to significantly mitigate the penetration of surface initiated pits into the steel substrate, which was translated in a lower volume loss. Local micro-delamination was found to be the main reason behind coating failure in presence of glycerol-based lubricants, as a result, pitting took place on the steel exposed areas.

Grease is among the most widely used lubricants in rolling element bearings. Proper understanding of the effect of lubrication due to grease aging can provide a significant increase in the life of the engineering systems. However, at present, there is no sufficient understanding of the grease aging effect in rolling elements bearing. This restricts the optimal usage of the bearing and timely monitoring of the grease. The current research work tries to address this issue with an experimental investigation. This project studies the behavior of 4 types of greases in rolling elements bearings for various operating conditions by recording the temperature and acoustic emission data. The aged samples were prepared to keep in the oven at 150 °C for a series of time duration letting it go through the chemical changes and thermal degradation. Tests were carried out in a test rig with the different levels of oxidized greases for 5 hrs time. And the effects in bearing temperature, acoustic emission were recorded. This is an investigation to analyze the effects of grease composition and aging in rolling elements lubrication by means of acoustic emission and bearing temperature. The IR spectroscopy was carried from the samples collected from the oven in order to understand the change in lubricant composition. The results show that the grease with di-urea thickener and base oil of synthetic ether and polyolester gives the best bearing temperature and acoustic emission behavior compared to the other grease type. The possibility of using the acoustic emission and temperature data to monitor the grease aging is also presented. Along with this, the possibility of using the AE statistical methods, AE count method, and energy plot were also explored to relate with the degree of aging.

The global shift towards sustainable practices extends across various domains, including energy generation. Wind energy, a cornerstone of this transition, relies heavily on the efficient operation of wind turbines. This study investigates the impact of contaminants on the longevity and performance of blade bearings in wind turbines. Under real-world conditions, blade bearings frequently operate in suboptimal lubrication environments, attacked by contaminants like wear particles and water. This research, conducted in collaboration with Vattenfall R&D, aims to focus on the specific effects of these contaminants.  Through comprehensive literature reviews and tribological tests, the study evaluates the load in rolling elements, examines the contact conditions between raceways and rollers, and determines the effects of contaminants on wear volume. Findings indicate that most pitch movements in blade bearings are limited to small angles, influencing lubrication requirements and wear patterns. Chloride-based EP additives, probably inactive due to insufficient activation temperatures, show potential for hydrolysis-induced corrosion.  Wear tests suggest that used grease may perform better under certain conditions compared to fresh grease, highlighting the complexity of lubricant performance. Long-term tribological tests show that FUCHS LUBRITECH GLEITMO 585K exhibits better wear resistance compared to Shell Rhodina BBZ in test conditions.  The study underscores the importance of proper lubrication and contamination management in extending blade bearing life. Recommendations include regular grease monitoring and analysis, understanding tribo-corrosion effects, and improving seal compatibility to enhance overall bearing reliability.

The main objective of this thesis work was to gain understanding of the principles of biolubrication, focusing on synergistic effects between biolubricants. To this end surface force and friction measurements were carried out by means of Atomic Force Microscopy, using hydrophilic and hydrophobic model surfaces in salt solutions of high ionic strength (≈ 150 mM) in presence of different biolubricants. There was also a need to gain information on the adsorbed layers formed by the biolubricants. This was achieved by using a range of methods such as Atomic Force Microscopy PeakForce imaging, Quartz Crystal Microbalance with Dissipation, Dynamic Light Scattering and X-Ray Reflectometry. By combining data from these techniques, detailed information about the adsorbed layers could be obtained.The biolubricants that were chosen for investigation were a phospholipid, hyaluronan, lubricin, and cartilage oligomeric matrix protein (COMP) that all exist in the synovial joint area. First the lubrication ability of these components alone was investigated, and then focus was turned to two pairs that are known or assumed to associate in the synovial area. Of the biolubricants that were investigated, it was only the phospholipid 1,2-dipalmitoyl-sn-glycero-3-phosphocholine (DPPC) that was found to be an efficient lubricant on its own. Deposited DPPC bilayers on silica surfaces were found to be able to provide very low friction coefficients (≈ 0.01) up to high pressures, ≈ 50 MPa. A higher load bearing capacity was found for DPPC in the liquid crystalline state compared to in the gel state.The first synergy pair that was explored was DPPC and hyaluronan, that is known to associate on the cartilage surface, and we also noticed association between hyaluronan and DPPC vesicles as well as with adsorbed DPPC bilayers. By combining these two components a lubrication performance similar to that of DPPC alone could be achieved, even though the friction coefficient in presence of hyaluronan was found to be slightly higher. The synergy here is thus not in form of an increased performance, but rather that the presence of hyaluronan allows a large amount of the phospholipid lubricant to accumulate where it is needed, i.e. on the sliding surfaces.The other synergy pair was lubricin and COMP that recently has been shown to be co-localized on the cartilage surface, and thus suggested to associate with each other. Lubricin, as a single component, provided poor lubrication of PMMA surfaces, which we utilized as model hydrophobic surfaces. However, if COMP first was allowed to coat the surface, and then lubricin was added a low friction coefficient (≈ 0.03) was found. In this case the synergy arises from COMP facilitating strong anchoring of lubricin to the surface in conformations that provide good lubrication performance. / Huvudsyftet med det här avhandlingsarbetet var att öka förståelsen för den låga friktion som finns i vissa biologiska system, med fokus på synergistiska effekter mellan de smörjande molekylerna. För detta ändamål studerades ytkrafter och friktion med hjälp av atomkraftsmikroskopi. Mätningarna utfördes med hydrofila och hydrofoba modellytor i lösningar med hög salthalt (≈ 150 mM) i närvaro av smörjande biomolekyler. Det var också nödvändigt att få information om de adsorberade skikten av biomolekyler. Det åstadkoms med hjälp av en rad tekniker så som AFM PeakForce avbildning, kvartskristallmikrovåg, dynamisk ljusspridning och röntgen reflektometri. Genom att kombinera data från dessa tekniker erhölls detaljerad information om de smörjande skikten.De smörjande biomolekyler som valdes ut för studierna var en fosfolipid, hyaluronan, lubricin, and cartilage oligomeric matrix protein (COMP) vilka alla finns i synovialledsområdet. Först undersöktes den smörjande förmågan hos dessa komponenter var för sig, och sedan fokuserade vi på två par av biomolekyler som man vet eller antar bildar associationsstrukturer i synovialleder. Av de enskilda biomolekyler som undersöktes var det endast fosfolipiden 1,2-dipalmitoyl-sn-glycero-3-fosfokoline (DPPC) som visade sig vara en effektivt smörjande molekyl. Deponerade biskikt av DPPC på silikaytor gav upphov till mycket låga friktionskoefficienter (≈ 0.01) upp till höga pålagda tryck, ≈ 50 MPa. DPPC bilager i flytande kristallin fas visade sig ha högre lastbärande förmåga än DPPC bilager i geltillstånd.Det första synergistiska par som undersöktes var DPPC och hyaluronan vilka man vet associerar på broskytan, och vi visade att hyaluronan associerar med såväl DPPC vesiklar som med DPPC bilager. Genom att kombinera dessa två komponenter uppmättes en smörjande förmåga som var jämförbar med den som DPPC ensam uppvisar. Även om friktionskoefficienten var något högre i närvaro av hyaluronan. Synergieffekten här består inte av en bättre smörjande förmåga, utan istället gör närvaron av hyaluronan att de smörjande fosfolipiderna kan ansamlas i stora mängder där de behövs, dvs. på de glidande ytorna.Det andra synergiparet var lubricin och COMP vilka nyligen har visats vara lokaliserade på samma platser på broskytan, vilket tyder på att de associerar med varandra. På egen hand var lubricins smörjande förmåga av PMMA, våra hydrofoba modellytor, dålig. Emellertid, om COMP först adsorberades på PMMA och sedan lubricin tillsattes uppmättes en låg friktionskoefficient (≈ 0.03). I det här fallet består synergin av att COMP möjliggör en stark inbindning till ytan av lubricin i konformationer som ger god smörjande förmåga. / <p>QC 20141202</p> / Stiftelsen för strategisk forskning - SSF

Abstract In the world where every sector of industrial manufacturing is being converted toautomated systems, surface finishing processes like sanding and polishing seem to lag.This phenomenon is not surprising as these processes are complex to optimize. Therehave been projects going on with the support of European Commission to findsolutions under SYMPLEXITY (Symbiotic Human-Robot Solutions for ComplexSurface Finishing Operations). One of the projects in under this include poliMATIC(Automated Polishing for the European Tooling Industry). Halmstad University isinvolved in doing projects. This project took a portion of this study in aim to understand a foam material’s behavior used for sanding tool at the tip of a robotic arm. This is studied using a forcemeasurement system developed at Halmstad University. The project has two sectionsand starts with one; Understanding the force measurement system and upgrading innecessary ways. Two; studying how the foam material compressive hardness propertyis affected when the material is fit with sandpaper for sanding operation using theforce measurement system. The study finally revealed how the combination of thefoam with sandpaper affects the robustness of the material, and significantlyimproved the output of the system with by reducing the noise level with 40%.

I deatta arbete har olika nötningstyper identifierats vilka entreprenadmaskiners skopor utsätts för. Utifrån de dominerande nötningstyperna ska en nötningsprovrigg konstrueras som behandlar dessa. Detta då företaget Borox som förser entreprenad och vägindustrin med slitstarka stålmaterial ska kunna testa sina material och få en relativ uppskattning om nötningsbeständighet och lämplighet på sina produkter.  En produktutvecklingsprocess följdes under arbetet och en lämplig provrigg valdes för att sedan konstrueras och ritas..

Hard chrome exhibit hardness of about 70 HRC and lubricity that prevents seizing and galling and is therefore the common first choice for engineers to reduce friction and minimize wear. These properties enable engineering applications such as cutting and drilling, especially in manufacturing, production and consumer good industries. Hard chrome has a wide set of functions as being decorative, corrosion resistant and ease cleaning procedures. Hence, electroplating is a common process to synthesize hard chrome butthis process is banned by EU due to the rise of hazardous components. However, the need for alternative material is at rise but, fundamental issues for hard chrome are yet to be solved. The purpose of the work is to develop atomic structures for two systems using different programs such as OpenMX, VESTA and Ovito. The goal is to identify atomic wear mechanisms of hard chrome in an ideal system (Al2O3- Cr) and a real system (Al2O3 - Cr2O3) using density functional theory (DFT). These two systems are analyzed since every surface oxidises in air (real system) and under increased mechanical loads the pristine surface of hard chrome (ideal system) can be exposed to the counter body (Al2O3). DFT based molecular dynamics simulations are carried out at a temperature of 300 K and a sliding speed of 10 ms−1. The simulation interval is 0-15000 fs and radial distribution function (RDF) is employed to analyse the atomic wear mechanisms. Both systems start to show adhesive wear due to amorphization, mixed with signs of abrasive wear on the atomic scale. The systems are further analyzed using electron density distribution (EDD), that plots electronic structures enhancing the analyse of different type of bondstaking place. The bulk structures mainly show covalent bonds with ionic and metallic bonds less represented. Furthermore, same observations have been made for the interfaces of the ideal and real system. / Hårdkrom uppvisar hårdhet på ungefär 70 HRC och en smörjförmåga som förhindrar nötning och är därför det vanliga första valet för ingenjörer att minska friktionen och minimera slitaget. Dessa egenskaper möjliggör tekniska tillämpningar, såsom skärning och borrning, särskilt inom tillverknings, produktions och konsumentvaruindustrin. Hårdkrom har ett brett användningsområde och flera egenskaper såsom att vara dekorativ, korrosionsbeständig och underlätta rengöringsprocedurer. Därav är galvanisering en vanlig process för att syntetisera hårdkrom, men denna process är förbjuden av EU på grund av utsläpp av farliga komponenter. Behovet av alternativt material är vid uppgång men, de grundläggande problemen för hård krom är ännu inte lösta. Syftet med arbetet är att ta fram atom strukturer för två system med hjälp av olika program, såsom OpenMX, VESTA och Ovito. Målet är att identifiera vilken typ av nötning som sker på hårdkrom i ett idealt system (Al2O3- Cr) och i ett verkligt system (Al2O3- Cr2O3) genom att använda täthetsfunktionalteorin (DFT). Dessa två system analyseras eftersom varje yta oxiderar i luften (verkligt system) och under ökade mekaniska belastningar kan den orörda ytan av hårtkrom (idealiskt system) exponeras för motkroppen (Al2O3). DFT simuleringar är skapade med en temperatur på 300 K och en glidningshastighet på 10 ms−1. Simulerings intervallet är från 0-15000 fs och med hjälp av radiell fördelningsfunktion (RDF) analyseras de atomiska nötnings mekanismerna. Båda systemen börjar visa adhesiv nötning på grund av amorfisering, samt ett tecken på abrasiv nötning på en atomisk skala. Systemen analyseras vidare med användning av elektrondensitetsfördelning (EDD) som plottar elektroniska strukturer vilket förbättrar analysen av olika typer av bindningar som äger rum. Bulkstrukturerna visar huvudsaklig en kovalent bindning med joniska och metalliska bindningar mindre representerade. Samma observationer har gjorts för gränssnitten mellan det ideala och verkliga systemet.

Magnesium with two-thirds of the density compared to aluminium and one-quarter of steel, intrigues product developers and material scientists due to the light metal’s excellent combination of strength to weight ratio as well as their capability of being produced as a High Pressure Die Cast component compared to other ferrous or light metal alloys.   However, a magnesium alloy inherits some concerning drawbacks, limiting the exploitation in structural applications and mechanical design such as automotive, heavy machinery and aerospace components. The need for a magnesium alloy that could withstand a sufficient amount of wear, temperature and corrosive environment, leads towards the investigation and evaluation of a suitable, functional coating as a solution to exploit the evident advantages a magnesium alloy exhibits. A substantial amount of research is required in order to reduce an existing knowledge gap that is the ongoing development in the search for a sufficient functional coating and adherence capability to the highly reactive substrate that is a magnesium alloy.   This industrial master thesis is an early stage investigation to evaluate how the currently used aluminium substrate with an electrodeposited coating relate and compares to a heat-treated electroless deposited coating through tribological and thermophysical induced stresses. These properties are tested with proven industrial standard methods resulted in a comprehensive conclusion and discussion regarding the feasibility of applying the coating onto a commercial magnesium alloy closely related to the Mg-alloy developed by Husqvarna and thereby contributing to technological advances to the highly relevant topic within product development in materials engineering.

High-performance materials such as stainless steels and nickel based super alloys are widely used in demanding applications where high mechanical and thermal properties are required. The applications of super alloys are mainly found in jet engines, power plants and gas turbines demanding high fatigue strength, corrosion and oxidation resistance as well as wear resistant properties. In order to use them, they go through various machining processes such as milling, turning, cutting, polishing etc. until the final product is achieved. Modern manufacturing industries employs various machining tools and technologies to improve the machining process of heat resistant super alloys. However, there are still challenges which needs to be addressed. Among them, adhesive wear of the machining tools is one of the main wear mechanism during the tribological interaction of tool and workpiece, preventing them to achieve the desired quality and surface finish of the end product. Moreover, it damages the tool reducing its lifecycle and in return, increasing the production cost. Among the cutting tools tungsten carbide (WC/Co) tools coated with TiAlN coating due to their good high temperature performance are extensively used. Nonetheless, these coatings still face issue like adhesive wear, abrasion, oxidation at higher temperature damaging the tools and subsequent machining. Therefore, it is imperative to understand the initiation mechanism of adhesive wear during the tribological interaction of super alloys and coated cutting tool material. In this research work, the tribological response of two coatings deposited by physical vapour deposition (PVD), having the composition Ti60Al40N and Ti40Al60N have been studied against two super alloys material, i.e. Inconel 718 and stainless steel 316L. A high temperature SRV (Schwingung (Oscillating), Reibung (Friction), Verschleiß (Wear)) reciprocation friction and wear test set up was employed to investigate the friction behaviour, wear rate and dominant wear mechanisms.  For Ti60Al40N coating, the experimental results revealed that generally, friction increases in case of sliding against Inconel 718 up to 400 °C and drops at 760 °C. A high wear volume at room temperature and a decrease to a minimum at 760 °C has been observed for Inconel 718. On the other side, Stainless steel 316L (SS 316L) faces a continuous rise in friction coefficient with highest value at 760 °C during sliding against Ti60Al40N coating. Wear is highest at 400 °C for SS 316L pin. The worn surfaces shows that both workpiece materials experience increase in material transfer due to adhesive wear with rise in temperature. At 400 °C, adhesion is the primary wear mechanism for both workpiece materials. A further rise in temperature to 760 °C promotes the adhesive wear through oxides formation on both material surfaces.  Similarly, Ti40Al60N coating shows the same friction behaviour with change in average steady state friction values for both material of Inconel 718 and SS 316L. Both workpiece materials responds in a similar way to wear volume loss, i.e. lowest at room temperature and highest at 760 °C. For Inconel 718, transfer of coating constituents on to the Inconel 718 pin surface was detected and associated with coating rupture and peeling, exacerbating with rise in temperature. Adhesion, abrasion, and oxidation are primary wear mechanisms at 400 °C and 760 °C. For SS 316L, coating transfer only happen at 400 °C. No damage of coating at 40 °C, a complete damage at 400 °C, and formation of dense porous oxides layers at 760 °C have been noticed. At 400 °C, adhesion, abrasion, and chipping while at 760 °C, adhesion, three body abrasion, ploughing and oxidation are the main wear mechanisms.