Demanding applications, as well as the push to eliminate the need for fossil-fuel based lubricants, create the need for the development of high-performance polymers. Polyphenylene Sulfide (PPS) is an example of a high-performance polymer and has a high service temperature, good dimensional stability, and excellent chemical resistance. However, it has a low impact strength and is very brittle in neat form. Another high-performance polymer, Polytetrafluoroethylene (PTFE), provides low friction in dry sliding conditions and can deposit polymer transfer films onto the counterface but exhibits high wear rates in neat form. To take advantage of the desirable characteristics of both polymers, PPS/PTFE-based composites were produced through the Injection Molding process. The individual disadvantages of these polymers were further improved by incorporating the following fillers: SCF, GO and CNT. The tribological performance under dry sliding conditions and two different loads were investigated as well as the microhardness and degree of crystallinity of the materials. The DSC results showed that the incorporation of reinforcements did not significantly alter the total degree of crystallinity in the material. PPS/PTFE and the composites have significantly lower specific wear rates and coefficient of friction values compared to neat PPS and PTFE. The composites have higher microhardness and friction coefficient values (60N and 100N) compared to PPS/PTFE. For both loads, composites SCFCNT, 5SCF and 10SCF had the lowest specific wear rates recorded where a synergistic effect between SCF and CNT has been observed. The filler loading content did not affect the friction performance of the composites in both loads. However, for composites with SCF as the only reinforcement, the increase in wt% content of SCF increased the specific wear rate at 60N and decreased the specific wear rate at 100N. SEM images of the pin surfaces show that the governing wear mechanisms in the polymer blend and composites are abrasive and adhesive wear. The reduction of the specific wear rate values is also accompanied by the improvement in the uniformity of the observed transfer film formation.

Målet med detta arbete är att undersöka smörjsystemet på två utsatta leder på en Boomer E2C. Förfrågan om examensarbetet kommer från Atlas Copco Rock Drills AB i Örebro som också tillverkar maskinen. Atlas Copco Rock Drills AB har idag ett fettsmörjningssystem som upprätthåller funktionerna på lederna. Uppgiften är att sammanfatta och utvärdera dagens system samt att finna nya lösningsförslag som skulle kunna ersätta eller delvis ersätta systemet. Information har hämtats från dokumentation, ritningar och samtal med konstruktörer på företaget. Efter att alla förutsättningarna för lederna specificerats så har lösningsförslag sökts. Genom att träffa lagerleverantörer och söka artiklar så har idéer formats. Brainstorming har använts för att kunna se nya lösningar. Undersökningen har visat att det finns problem med dagens lösning vad gäller slanghaverier och driftstopp i fält. Atlas Copco AB uttrycker även att kunskapen och dokumentationen angående systemet är otillräckligt. Efter artikelsökning så kan konstateras att forskningen och kunskapen på området med tungt belastade, oscillerande och fettsmörjda leder är liten. Dimensionering sker ofta med hjälp av erfarenhet och med tankesättet ”det har fungerat förut”. När lösningsförslagen har jämförts så har detta gjorts genom att använda metoden AHP (Analytic Hierachy Process). Med denna metod så jämför man kriterierna från kravspecifikationen med lösningsförslag så att man matematiskt kan räkna fram ett vinnande lösningsförslag. Resultatet visar att en smörjfri lösning skulle teoretiskt vara att föredra. Denna skulle tillverkas av en modern polymer och kompletteras med en inre tätning och ett yttre skydd. Atlas Copco rekommenderas att testa de olika förslagen för att komma fram till vilken som är bäst lämpad för applikationen. / The goal of this work is to investigate the lubrication system on two exposed joints on a Boomer E2C. The request for the thesis comes from Atlas Copco Rock Drills AB, Örebro, which also manufactures the machine. Today Atlas Copco Rock Drills AB has a grease lubrication system that secures the function of the joints. The task is to summarize and evaluate the current systems and to find new solutions that would be able to replace or partially replace the current system. Information was gathered from documents, construction drawings and conversations with engineers at the company. Solutions and ideas have been formed by meeting stock suppliers and searching for articles. Brainstorming has been used in order to find new solutions. The investigation has shown that there are problems with the current solution in terms of hose failures and downtime in the field. Atlas Copco AB also expresses that there is a lack of documentation and knowledge regarding the lubrication system. After the various article searches it became clear that research and knowledge in the area with heavy duty, oscillating and grease lubricated joints is insufficient. The design is often done with the help of experience and with the mindset "it has worked before." When the solutions and ideas have been compared, this has been done by using AHP (Analytic Hierarchy Process). This method compares the criteria that must be fulfilled by the solutions and then calculates the best one. The results show that a lubrication-free solution would theoretically be preferable. This would be produced by a modern polymer and supplemented with an inner seal and an outer protection. Atlas Copco is recommended to test the various proposals to be able to decide which the best solution for the application is.

This thesis summarizes the work done on tribological characterization of multifunctional hardfacing coatings with self-lubricating properties, intended for use in mechanical components operating in high temperature applications for which conventional lubricants are no longer effective. Deposition techniques like laser cladding have a great potential in reworking/repair of high value industrial components in order to extend their lifetime. It is expected that the use of self-lubricating laser claddings could be useful in high temperature applications like metal forming, leading to decreased friction and wear. In this study, the tribological behavior of self-lubricating claddings has been studied against steel and aluminum counter surfaces, using ASI52100 bearing steel in addition to AA6082 and AA2007 aluminum flat pins as the counter bodies. Nickel- and iron-based powders have been chosen for the preparation of claddings. Self-lubricating properties of Ag/MoS2 have been compared to an untreated reference cladding and grade 1.2367 tool steel. For steel counter surfaces, tribological properties in the temperature range between RT and 600⁰C have been investigated and at 300°C for aluminum counter surfaces. Tribological tests were done by a high frequency linear oscillation (SRV) test machine under reciprocating conditions. The wear scar and volume of coatings were measured by using a 3D optical profilometer. SEM/EDS analysis were additionally performed for the characterization of microstructure and wear scar. The results indicated that MoS2 reduced friction and wear of the Fe-based cladding material when tested against steel at room temperature compared to the reference alloy and grade 1.2367 tool steel, and that the addition of silver further decreased wear in addition to early stage friction. It was also observed that the tribolayer, which was formed during the sliding of Ni-based - 5 Ag - 10 MoS2 and against aluminium under lubricated conditions, was protective and provided low and steady friction.

The purpose of the project work was to build knowledge of the tribological behaviour of self-lubricating laser cladding, with and without external solid lubricant during conditions relevant for hot metal forming of aluminium. The materials used during the project were plates coated with a Ni-based self-lubricating clad and a reference sample of work tool steel. The self-lubricating laser clad was applied using a high power direct diode laser. The external solid lubricant used was a graphite dispersion. The external solid lubricant was applied on the samples using a spraying technique, leaving a dry layer of solid graphite on the plates. To test the tribological behaviour of the plates, linear reciprocating friction and wear tests were performed both under lubricated and dry conditions. During the dry tests, different surface roughness of the plates where investigated. The pins for the tribological test were made of AA7075. Parameters chosen for the tribological tests were based on conditions during hot forming of aluminium. After having taken images of the plates using scanning electron microscopy, and using a 3D optical profiler, the wear volume and material transfer was evaluated, and wear mechanism analysis was performed.   The tribological behaviour of polished Ni-based laser clad under dry conditions is comparable to that of the reference sample at its best performance. Using a mirror polished Ni-based laser clad under dry condition can be an option to not using external solid lubricant during hot forming of aluminium. Also, the surface roughness of the self-lubricating clad under dry conditions does not affect the coefficient of friction.