The purpose of the present PhD research project was to evaluate the feasibility of the electrodeposition of novel thin Ni composite coatings with lubricant particles from an additive-free Watts bath and their application as diffusion barrier layers in journal bearings for medium-speed diesel engines. Overall, the main objective was to develop thin Ni composite coatings with the following characteristics: • Improved tribological performance. • Good adhesion properties. • Good ‘anti-diffusion’ performance. Ultrasound was used in the preparation of pure Ni coatings and Ni composite coatings with lubricant particles under different conditions in order to understand how ultrasonic cavitation influences electrodeposition and characteristics of said Ni-based coatings. Two main studies were conducted related to this: 1. Study of the effect of ultrasonic power on the electrodeposition of pure Ni coatings to understand the influence of cavitation phenomena near the surface of the cathode on the properties of Ni deposits 2. Study of the effect of ultrasound on the production of Ni composite coatings to understand the influence of ultrasound in the dispersion of particles, the electrodeposition of Ni composite coatings and the properties of said Ni composite coatings. The influence of ultrasound on the dispersion of particles in the Watts bath was evaluated by observing the visual appearance of the resulting dispersions and analysing the particle size distribution of diluted solutions by laser diffraction-based particle sizing methods. The effect of ultrasound on the characteristics of Ni deposits and Ni composite coatings electrodeposited from the additive-free Watts bath was evaluated by different material characterization techniques: Abstract • X-Ray Diffraction (XRD) analysis was employed to observe the orientation of the Ni crystals that formed the coatings. • Field Ion Beam – Scanning Electron Microscopy (FIB-SEM) was employed to analyse the surface morphology and microstructure of the coatings. • Microhardness tests were performed to observe how the modification of the grain structure and the presence of particles may affect the hardness of the coatings. • Glow Discharge – Optical Emission Spectroscopy (GD-OES) was also employed to estimate the particle content in the Ni composite coatings.

De nombreuses pièces sont sujettes à des sollicitations de frottement à haute température dans le domaine de l’aéronautique. En effet, dans ce domaine, l’augmentation constante des puissances des réacteurs implique une augmentation de la température de fonctionnement des systèmes mécaniques et en particulier des contacts frottants. Cette augmentation de température a pour conséquence la diminution de la durabilité des matériaux lubrifiants solides actuellement utilisés pour ce type de contact. C’est pourquoi il est indispensable de sélectionner de nouveaux revêtements aux propriétés tribologiques à chaud améliorées. Dans cette optique, une thèse ayant pour sujet la durabilité de rotules aéronautiques d’attache mât-moteur de l’A380 soumises à des conditions extrêmes de fonctionnement en termes de température et de conditions glissement, a été effectuée au LTDS. Dans un premier temps, les endommagements de surface (abrasion, adhésion) des pièces réelles ont été analysés, à travers des analyses MEB/EDX du revêtement d’argenture déposé dans le contact entre les bagues intérieure et extérieure de la rotule. Des essais tribologiques en configuration classiquement utilisée, cylindre/plan (sur Cameron-Plint), ont ensuite été réalisés sur le revêtement d’argenture afin de comparer les endommagements observés in situ et sur banc. Dans le but de sélectionner un revêtement ou un couple de revêtements susceptibles de remplacer l’argenture dans le contact étudié, une dizaine de revêtements différents (couches accommodantes et couches dures) ont ensuite été testés individuellement en configuration cylindre/plan dans les mêmes conditions d’essai que dans le cas de l’argenture. Cette campagne d’essai a permis de dégager les plus performants/endurants tribologiquement. Parallèlement, un tribomètre original a été conçu au laboratoire afin de pouvoir simuler au mieux les conditions de contact réelles (sollicitations mécaniques, température de contact…). Ce tribomètre rotatif à haute température (TRHT), utilisable en configuration couronne/plan, permet d’appliquer simultanément au contact une force normale pouvant aller jusqu’à 50 kN, un mouvement rotatif alternatif, et une température de contact pouvant aller jusqu’à 1000°C grâce à un système de chauffage par induction. Les revêtements ayant démontré le meilleur comportement en termes de résistance à l’usure et au frottement au cours des essais en configuration cylindre/plan ont également été testés individuellement sur ce tribomètre en configuration couronne/plan. Les essais finaux ont été réalisés en interface complète, c'est-à-dire avec une couche accommodante déposée sur la pièce représentant la bague intérieure de la rotule, une couche dure déposée sur la pièce représentant la bague extérieure, et une couche à bas frottement (graisse ou vernis). Deux solutions de lubrification de ce type ont été déterminées pour le contact rotulé : une pour les rotules d’attache mât-moteur avant qui fonctionnent jusqu’à 160°C (CuNiIn + vernis Everlub / WC-C) et une pour les rotules d’attache mât-moteur arrière qui fonctionnent jusqu’à 570°C (stellite + vernisEverlub / TiHfCN). / In aeronautics tribology, mechanical parts are required to operate with increasing temperature. The increased functioning temperature of the contacts prone to friction and wear (such as bearings and other structural parts) is a direct consequence of the increasing power of jet engines. In the case of ball bearings, the substrate materials as well as the coating durability are affected by temperature. There is then a pressing need to introduce new coatings demonstrating effective tribological behaviour at high temperature. A PhD research subject was defined in partnership with Airbus Aerospace and SKF Aerospace and conducted at LTDS. The main goal of this research is to study the durability of ball bearings functioning under extreme conditions in terms of temperature and sliding friction. First, SEM/EDX analyses were done on the silver coating deposited in the contact between the ball bearings rings, in order to acknowledge the actual bearings surface damage. Tribological testing of the silver coating was then performed in a standard cylinder-on-flat configuration in order to compare in situ and experimental damages. More than ten different coatings (both soft and hard coatings, with solid lubrication properties and/or wear resistance properties) were then tested in the same configuration and conditions as the silver coating. These tests allowed us to identify the best suitable coatings for the application. An original test rig was also designed in the lab, in order to better simulate the bearings functioning conditions. This tribometer (TRHT) makes it possible to perform tests in ring-on-flat configuration (close contact) and to simultaneously apply a normal force up to 50 kN and a reciprocating rotating motion. Using this tribometer, the final tests were conducted on the best candidates among the different coatings, individually at first to assess their tribological behavior, and then in a configuration as close to reality as possible, with a hard coating covered ring and a soft coating covered flat, the contact between the two being greased or varnished. Finally, several possible solutions were determined, for two different functioning temperatures:160°C (CuNiIn + varnish Everlub / WC-C) and 570°C (stellite + varnish Everlub / TiHfCN).

Les applications tribologiques des matériaux cellulaires en présence de liquide nécessitent une connaissance de leurs modes d’endommagement, mais elles restent peu connues à l’heure actuelle. L’étude, la compréhension et la modélisation du comportement d’un matériau composite cellulaire nécessitent une approche pluridisciplinaire due au caractère hétérogène du matériau qui reste difficilement caractérisable. Ce matériau peut être analysé suivant 3 axes bien distincts : les propriétés rhéologiques (analyses sous état de déformation complexe en compression et en cisaillement avec des rhéomètres adaptés), la morphologie des alvéoles (analyses 3D optiques et tomographiques), les propriétés tribologiques (analyse en frottement de l'interface et des particules d'usure). L’intérêt majeur de notre approche est d'aborder simultanément ces 3 axes et de comprendre leurs interactions respectives. La tomographie aux rayons X, suivie d’un traitement mathématique assisté par ordinateur, complété par l'analyse des particules d'usure a permis d'identifier les morphologies responsables des fonctions spécifiques du matériau cellulaire. Un tribo-abrasimètre innovant avec des surfaces abrasives modèles a mis en évidence l’importance des cinématiques dans l’endommagement du matériau. Des méthodes de caractérisation ont été mises au point afin de quantifier la dégradation tribologique du matériau permettant également de mesurer l’impact du vieillissement (chimique, thermique et mécanique). / Tribological applications of cellular materials in the presence of liquid require acknowledge of their modes of damage, but they remain little known at present. The study, understanding and modeling the behavior of a composite cell requires a multidisciplinary approach due to the heterogeneity of the material that is difficult to characterize. This material can be analyzed along three distinct axes: the rheological properties (analysis in complex state of deformation in compression and shear with adapted rheometer), the morphology of the cells (3D optical tomographic analysis), the tribological properties (analysis in interface friction and wear particles). The major advantage of our approach is to simultaneously address these three areas and to understand their interactions. The X-ray tomography, followed by computer-assisted mathematical treatment, supplemented by the analysis of wear particles identified morphologies responsible for specific functions of cellular material. A tribo-abrasimeter with innovative models abrasive surfaces highlighted the importance of kinematics in the damage of the material. Characterization methods have been developed to quantify the tribological degradation of the material can also measure the impact of aging(chemical, thermal and mechanical).

Lamellar graphite iron (LGI) is commonly used in diesel engine applications such as piston rings–cylinder liner where an excellent combination of physical and tribological properties is essential to avoid scuffing and bore polishing issues. The excellent tribological behaviour of LGI alloys is related to the graphite lamellas, which act as solid lubricant agents by feeding onto the tribosurfaces under sliding conditions. However, increasingly tighter emissions and fuel economy legislations and the higher demands on enhanced power and durability have encouraged both engine designers and manufacturers to introduce pearlitic compacted graphite irons (CGI) as an alternative material replacing LGI, although the poor machinability of pearlitic CGI alloys compared to the LGI remains a challenge. The focus of this study is placed on investigating how the microstructure of LGI and CGI alloys affects their mechanical and tribological properties. This was initially undertaken by investigating representative, worn lamellar cast iron piston rings taken from a two-stroke large-bore heavy-duty diesel engine. As known that it is tribologically essential to keep the graphite open under sliding conditions, in particular under starved lubrication regimes or unlubricated conditions to avoid scuffing issues; however, this study revealed the closure of a majority of graphite lamellas; profoundly for those lamellas that were parallel to sliding direction; due to the severe matrix deformation caused by abrasion. Both microindentation and microscratch testing, which were used to crudely simulate the abrasion under starved lubricated condition in combustion chamber, suggested a novel mechanism of activating the graphite lamellas to serve as lubricating agents in which the matrix deformation adjacent to the graphite initially resulted in fracturing and then extrusion of the graphite lamellas. Additionally, in order to investigate the relation between matrix constituents, mechanical properties and machinability of cast iron materials, solution-strengthened CGI alloys were produced with different levels of silicon and section thicknesses. The results showed significant improvements in mechanical properties and machinability while deteriorating the ductility. Moreover, multiple regression analysis, based on chemical composition and microstructural characteristics was used to model the local mechanical properties of high Si ferritic CGI alloys, followed by implementing the derived models into a casting process simulation which enables the local mechanical properties of castings with complex geometries. Very good agreement was observed between the measured and predicted microstructure and mechanical properties.

There is a increasing emphasis in today’s world to use environmental friendly solutions for tribological and lubrication purposes. Use of water as a lubricant presents a cost effective and easy method of bio friendly lubrication. But, as water has low viscosity, it is necessary that the materials used in water lubricated contacts perform exceedingly well in boundary lubricated conditions. Polymer Based Materials (PBMs), are one such group of materials which have been proven to perform well in such conditions. In particular, Ultra High Molecular Weight Polyethylene (UHMWPE) has been extensively used in water lubricated contacts. But, PBMs still suffer from wear and related problems and there is room for improvement. Various methods have been tried with mixed results to improve the qualities of polymers and consequently their performance in water lubricated contacts. One such method is by inclusion of fillers. Conventionally, micron sized fillers have been used to form composites with a polymer resulting in materials with better properties. Recently, nanometer sized reinforcements have been attracting more attention due to their unique mechanical and tribological properties. Combining micrometer and nanometer sized filler in a polymer composite could help form materials with excellent properties. Such composites would be termed as a hybrid material. Therefore, the aim of this project and thesis is to experimentally investigate the influence and interaction of micro and nano carbon-based fillers on tribological behaviour of UHMWPE composites and provide further understanding of the mechanisms involved.

I pappersmaskiner används kräppblad för att kräppa av pappret från en stor roterande cylinder, en så kallad yankee-cylinder. Dessa blad utstår stora nötningar och beläggs därför med antingen en kromoxidbeläggning eller en hårdmetallsbeläggning för att öka bladets nötningsbeständighet. Bladen beläggs med termisk sprutning, kromoxiden via plasmasprutning och hårdmetallen via "High-Velocity-Oxy-Fuel"-sprutning (HVOF). I detta arbete har slitagetester utförts på belagda kräppblad genom att använda en "slider-on-flat-surface" (SOFS) tribometer för att ta reda på vilken av dessa beläggningar som är bäst lämpad för att användas på kräppblad. Vid användning av SOFS belastas kräppbladen med en normalkraft och glider mot en platta till önskad total glidsträcka är uppnådd. För att kunna genomföra slitagetesterna i SOFSen behövdes en fixtur konstrueras och tillverkas och kräppblad behövde kapas till önskad geometri. Det skapades tre koncept för fixturen och med en beslutsmatris gjordes valet vilken av dem som skulle tillverkas. Den tillverkade fixturen håller kräppbladen stabila i både sidled och i glidriktningen och håller kräppbladen i en vinkel likt i verkligheten. Slitagetesterna utfördes vid tre olika glidsträckor med konstant normallast. Efter slitagetesterna analyserades bladen i stereomikroskop och svepelektronmikroskop för att identifiera nötningsmekanismer. De dominerande nötningsmekanismerna var abrasiv och adhesiv nötning. På grund av porositet i beläggningarna ökades antalet sprickor och mer och mer fragment lossnade vid ökande glidsträcka under slitagetesterna. Det visade sig efter mätningar av bortnött bredd på bladet att det hårdmetallbelagda kräppbladet hade bäst nötningsbeständighet. Detta på grund av dess hårda tungstenkarbider som minskade den abrasiva nötningen och spricktillväxten i beläggningen och dess högre duktilitet jämfört med kromoxiden. / Creping blades are used in paper machines for creping tissue paper from a rotating cylinder called a yankee cylinder. These blades experience severe wear and are therefore coated by either chromium oxide or a hard metal coating to make the blades more wear resistant. The coatings are sprayed on to the blade by thermal spraying processes, the chromium oxide coating with plasma spraying and the hard metal coating with "High-Velocity-Oxy-Fuel" (HVOF) spraying. In this thesis wear testing of the coated creping blade using a "slider-on-flat-surface" (SOFS) tribometer has been done to find out which of these coatings that is best suited for coating on the creping blade. When using the SOFS, the creping blade is subjected to a chosen normal force and is scraped against a counterface for a set total distance. In order to execute the wear tests in SOFS, construction and manufacturing of a holder for the creping blades was needed and the creping blades had to be cut to correct geometry. Three concepts were created for the holder and the decicion about which one to manufacture was made with a decision matrix. The new holder holds the creping blades stable in side movements and in the sliding direction. It also keeps the blade at a set angle to the counterface as in the real application. The wear tests consisted of three sliding distances with constant normal load. The blades were analyzed in a stereo microscope and in a scanning electron microscope to identify the wear mechanisms when the wear tests were completed. The major wear mechanisms were abrasive and adhesive wear. Because of porosity in the coatings, the number of cracks increased and fragments from the blades came loose when increasing the sliding distance during the wear tests. It showed that by measuring the eroded width on the blades that the hard metal coated blade had the best wear resistance because of the hard tungsten carbides that lowered the abrasive wear and the crack growth in the coating and because of its higher ductility in comparison to chromium oxide.

The automotive industry is constantly being challenged by customers and authorities to enhance the efficiency of the internal combustion engine (ICE) in order to achieve improved fuel consumption and reduced emissions. There are several interfaces within the design of an ICE that causes frictional losses, one of them is the valvetrain. An approach to reducing the friction in the valvetrain of modern engines is to implement cam-follower rollers, resulting in a rolling rather than sliding contact when interacting with the camshaft. The prominent type of wear in rolling contacts is surface fatigue, and specifically a phenomenon called micropitting. The company in collaboration with this project is Applied Nano Surfaces Sweden AB (ANS), located in Uppsala, Sweden. The company have specialized in surface treatment methods of mechanical components. ANS has developed a mechano-chemical treatment method called ANS Triboconditioning, which have shown beneficial friction and wear reducing properties when applied to metal surfaces. This thesis was conducted to investigate how the ANS Triboconditioning would affect the frictional behaviour compared to established surface treatment methods and the occurrence of micropitting in rolling contact configurations. Two types of test programs was implemented into a Wazau UTM 2000 Twin-Disc Tribometer. No clear trend could be established from the micropitting tests and therefore no conclusion regarding if ANS Triboconditioning affects the occurrence of micropitting damage in a positive or negative manner could be stated. The results from the friction test indicated an overall reduction in friction for the test specimens that had been treated with ANS Triboconditioning when compared to specimens that only had been treated with already established surface treatment methods. Summarized, additional tests and analyses are necessary in order to statistically confirm the observed results and determine their respective trends.

Foram realizados ensaios tribológicos do tipo pino-disco com pinos de cobre puro, alumínio e latão para sob cargas normais de 10, 20 e 50 N contra discos de aço, que foram analisados após os ensaios utilizando interferometria óptica 3D e microscopia eletrônica de varredura. O par tribológico cobre-aço apresentou curva de coeficiente de atrito instável, com valor médio de 0,65. Os pares alumínio-aço e latão-aço apresentaram curvas de coeficiente de atrito mais estáveis que aquelas apresentadas nos ensaios com pinos de cobre, com valor médio de coeficiente de atrito de 0,42 e 0,30, respectivamente. Tanto nos discos ensaiados com pinos de cobre quanto nos pinos ensaiados com pinos de alumínio observou-se a formação de filmes ricos em oxigênio. A formação de ilhas de cobre metálico provocou a instabilidade do comportamento do coeficiente de atrito do par cobre-aço, enquanto que o par alumínio-aço teve um comportamento mais estável devido as ilhas de óxido de alumínio. Nos ensaios utilizando pinos de latão, por sua vez, a presença de chumbo e oxidação moderada da superfície foi responsável pelo menor e mais estável coeficiente de atrito dos três pares tribológicos. O aumento da carga normal não alterou o comportamento do coeficiente de atrito, porém teve influência na formação das camadas de material aderido do pino na superfície dos discos. / Pin on disc tribotests were performed with copper, brass and aluminium pins tested against steel discs under normal loads between 10 and 50 N and characterized by means of laser interferometry and SEM. Copper-steel tribotests showed an unstable coefficient of friction curve around 0.65. Aluminium-steel and brass-steel tribopairs featured stable coefficient of friction curves, around 0.42 and 0.30, respectively. Both copper-steel and aluminiumsteel pairs presented oxygen rich transfer films. An adhesion of metallic copper patches caused the unstable coefficient of friction for the copper-steel, whereas for the aluminium-steel tribopair, the oxide layer controlled the coefficient of friction behaviour. An oxygen rich layer with some lead controlled the coefficient of friction for the brass-steel tribopair. Increasing the normal load did not affect the coefficient of friction but affect the formation of transfer layers.

Cone crushers are widely used in the mining, mineral processing and quarrying segments of the industry to crush ores and large rocks. In such machinery, the load to be carried is rather heavy and the motion is gyratory which creates a need for a bearing set that can withstand such severe conditions. Sandvik AB is a high-technology Swedish engineering group specialized in tools and tooling systems for metal cutting, equipment, as well as tools and services for the mining and construction industries. One of their products relevant to the mining industry is the cone crusher which utilizes a 3-piece bearing set to carry thrust load. This bearing can be classified as a Spiral Groove Bearing \footnote{The abbreviation S.G.B will be used interchangeably throughout the thesis.}, and it has been incurred that it wears out rather quickly and is believed to be running under mixed-lubrication conditions where the interfaces in the bearing-set are not fully lubricated. The aim behind this thesis is to create a multiphysics model of this bearing in order to understand deeply how it works and the reasons why it does not perform as expected as well as to predict design improvements which can improve the performance of the bearing-set, thus increasing its operating life. It has been concluded that the bearing operates under severe mixed-lubrication conditions and that the generation of a squeeze film is the only method by which lubrication takes place due to the excessive depth of the grooves which is needed to allow for an adequate amount of cold oil to flow into the grooves and cool the interface as well as to accommodate for a considerable amount of wear particles. In light of the results and insight gathered from the simulations, possible design variations of the bearing which can be advantageous in terms of mitigating asperity friction in the interfaces of the bearing are discussed and tested.

[pt] O presente trabalho teve como objetivo central o estudo das modificações nas propriedades estruturais, mecânicas e tribológicas causadas pela incorporação de nitrogênio em filmes de diborato de titânio (TiB2) crescidos pela técnica de erosão catódica assistida por um campo magnético. Os revestimentos de Ti-B-N com diferentes conteúdos de nitrogênio foram depositados em substratos de silício cristalino (100) a partir da erosão de um alvo de diborato de titânio mediante o uso da técnica de erosão catódica em uma atmosfera de argônio e nitrogênio e com tensões de polarização variando entre +100V e - 100V. Os efeitos do conteúdo de nitrogênio e a influência da tensão de polarização na estrutura e no comportamento tribológico foram investigados com o uso da técnica nuclear de retroespalhamento Rutherford (RBS), espectroscopia de fotoelétrons induzida por raios-x (XPS), difração por raios-x (XRD), perfilometria (medidas de tensão interna), microscopia de força atômica (AFM) e de ângulo de contato. Os resultados do presente trabalho mostraram que a incorporação de nitrogênio produz filmes com tensões internas cada vez mais compressivas. No entanto a mudança da tensão de autopolarização a valores positivos provocou uma relaxação na tensão interna. Nesses casos, foi observada uma melhor adesão dos filmes aos substratos de silício. Os resultados de XPS mostraram que as fases, TiB2, BN e TiN, estão presentes nos filmes de Ti-B-N e a caracterização por XRD determinou a estrutura nanocristalina desses revestimentos. Medidas de AFM indicaram valores de rugosidade superficial entre 1 e 2nm. / [en] The main purpose of the present work was the study of the effects on the structural, mechanical and tribological properties of the incorporation of nitrogen in titanium diboride films (TiB2) grown by reactive dc magnetron sputtering. Ti-BN coatings with different N contents were deposited on Si (100) substrates from a TiB2 target. The sputtering was carried out in an Ar-N2 gas mixture with a substrate bias voltage in the range between +100V e -100V. The effects of the nitrogen content and the influence of substrate bias voltage on the coatings properties were studied by Rutherford Backscattering Spectrometry (RBS), XRay photoelectron spectroscopy (XPS), X-Ray diffraction (XRD), profilometry (internal stress measurements), atomic force microscopy (AFM) and contact angle measurements. The results of the present work show that nitrogen incorporation produces films with higher compressive internal stress. However, a positive substrate bias reduces the compressive stress, thus resulting in a better adhesion to the substrate. The XPS results showed that the TiB2, TiN and BN phases are present in the Ti-B-N films. Characterization by XRD determined the nanocrystalline structure of Ti-B-N coatings. Measurements by AFM revealed low surface roughness values.