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© IK4-TEKNIKER 2016
The Importance of Tribology in Demanding Industrial ApplicationsDr. Amaya Igartua, Dr. R. Bayon, Dr. A. Aranzabe, J. Laucirica, [email protected];
© IK4-TEKNIKER 2016
CONTENT
1. IK4-TEKNIKER general presentation
2. Introduction Tribology
3. Tribology in aggressive environments
4. Tribology of mechanical components
5. High temperature Tribology
6. Tribology of soft materials
7. Tribolubrication
8. Conclusions
© IK4-TEKNIKER 2016
IK4-TEKNIKER
© IK4-TEKNIKER 2016
RELEVANCE OF TRIBOLOGY
© IK4-TEKNIKER 2016
THE TRIBOLOGY UNIT• A well established unit with 35 years experience in Tribology
• National and European Reference in Tribology:
• Participation in more than 120 projects (EU, nacionals y regionals) specific
around tribology
• >250 contributions in reviews, congress and especialized books. 3 patents
• Congress Organization Collaboration: IBERTRIB, LUBMAT, World
Tribology Congress
• Participation in several national and international associations: International
Wearcheck group, EUMAT Secretary, World Tribology Council, Materials for
Energy (EMIRI), ECP4 (Plastic and composites), CAPTECH (Materials for
defense), JTI (Biomass industries).
• A team of 20 persons with accumulated experience during several years in
tribological subjects with 5 PHD in the team (8 PHD in September),
• Complete laboratory with 20 tribometers, 3 potentiostat. Wide variety of
tribological problems can be dealed.
• Direct Colaboration with other Units from IK4-TEKNIKER highly related to
tribology:
• Maintenance
• Failure diagnostics
• Oil analysis
• Mechanical design, sensors, robotics
• Physics and Chemistry of surfaces
• Láser, micro and nano machining
© IK4-TEKNIKER 2016
Tribological Solutions available at IK4-TEKNIKER
• PVD coatings
• PEO coatings
• Laser surface texturing
• Laser cladding (laser melting deposition)
• Sol gel
50X 100X 200X
© IK4-TEKNIKER 2016
NEED: To evaluate material capability, tribochemistry, tribodesorption and tribomechanisms under
vacuum or ultrahigh vacuum conditions, controlling their volatility (total mass loss, collected volatile
material, water regained).
WHY: Titanium is a light component, widely used in aerospace application because of their good
mechanical properties, but has bad tribological properties.
SOLUTIONS: Lubricants or Ionic liquids with low volatility to work under vacuum and ultrahigh
vacuum.
HOW: Developing a protective film or tribofilm by chemical reactions surface/lubricant in the sliding
contact. Tribochemical reaction.
CAracterization:
Tribochemistry
Tribodesorption analysis
Tribomechanism
- Friction and wear at Ultra High Vacuum
CA3UHV-CATRI
Home Made New testing equipments Vacuum and Ultrahigh Vacuum
© IK4-TEKNIKER Machines
DEMETRA
Total Mass loss
Collected volatil
condensable
material
Water regained
ASTM E595
Tribology in Agressive Environment: Vacuum
© IK4-TEKNIKER 2016
Triborectivity
Studies: Ionic liquids (halogen, or
Halogen free) to lubricate Ti, Steel
Actions: Testing friction, Wear,
Corrosion, tribocorrosion, vacuum
Interest:
• Low friction
• Wear and corrosion resistance
• Tribocorrosion resistance
• Tribodesorption control
• Tribolayer formation
Ionic liquids as Lubricants in atmospheric and vacuum conditions
High performance fluids and additives
XTRIBOLOGY-COMET
Tribology of Ionic Liquids
a b c
© IK4-TEKNIKER 2016
Novel Maintenance Concepts Mechanical & Chemical Wear + their Synergy
Coatings: PVD (arc, sputtering hippims), PEO
Solutions: Surface texturing, Roll to Roll, paints,
roughness
Actions:
•Corrosion, Wear, tribocorrosion resistance
Application: Biomedical, turbines, off shore, marine
Use minimum chemomechanical wear
Tribocorrosion
Tribology in aggresive environment: Tribocorrosion
TiN/CrN
Nadia, Ralpe, EmaitekFoulXPel, Alella, Funcoat
© IK4-TEKNIKER 2016
In Off shore, Marine Environmentally friendly antifouling & anticorrosion solutions
Coating: Environmentally antifouling Coatings.
Solutions: Surface treatment (Roll to Roll, paints,
texturing) to reduce fuel consumption
Actions:
•Testing drag friction (reduce)
•Texturing (control cell adhesion)
•Corrosion, Wear (reduce)
•Antifouling properties (tribobioadhesion)
•Paint release ecotoxicity tests (minimize)
Results: Benchmarking Solutions
maintenance rules.
Environmentally friendly antifouling (Tribobioadhesion) & anticorrosion solutions
mcqHCaT 425.0
0,00E+00
1,00E-03
2,00E-03
3,00E-03
4,00E-03
5,00E-03
200 500 1000 1500
Dra
g F
ricti
on
Speed (rpm)
Drag friction
;)(
Re
aba
Bacteria ISO 11348 Alga growth OECD 201
ShipsMotrico Port
50X 100X 200X
Tribology in aggresive environment: Tribobiocorrosion
© IK4-TEKNIKER 2016
Medical Applications: hip & Knee Prosthesis Antibacterial & tribocorrosion resistant solutions
Coatings: TiCN coatings & PEO Coatings
Antibacterial Solutions: Silver, Iodine,..
Actvities:
•Tribological & tribocorrosion tests
•Fretting tests
•Antimicrobial (control bacteria tribobioadhesion)
•Results: increase of durability of hip and knee
prosthesis, avoiding infection
PVD Coatings and PEO coatings
Tribology in aggresive environment: Tribobiocorrosion
Bacterial adhesion (friction phenomena)
© IK4-TEKNIKER 2016
Testing components efficiency
Studies: Light brakes, squeal-free
& high efficient clutches
Actions:Testing & modelling
Construction of testing benches.
Interest :
• High Durability
• Asbestos free pads
• Control dust emissions
• Resistance to fadding
• Constant high friction, high efficiency
• Noise reduction
Testing durability and squeal of Brakes & Clutches
Novel Product design, Manufacturing & Maintenance
Brakesqueal, Jolie, I-Sinter
Tribology of mechanical components: Brakes & Clutches
Clutch test vs Pin on Disc
© IK4-TEKNIKER 2016
Testing components efficiency
Studies: geometrical errors (α, Fα, Fβ, Fp),
materials, coatings
Actions:Testing & modelling
Interest: Durability, noise reduction
Testing durability of gears
Sensors Signalscollected
Acelerómeters Vibration (X, Y, Z)
Transducer in the axis of the Wheeland in the axis of the pinion
Transmissionerror
Torque sensor at the axis entry and in the Wheel axis.
Power loss
Microphone Noise
Termocouple PT-100 Temperature
Drive motor Intensity
PittingMicropitting band Scuffing
Novel Product design, manufacturing & Maintenance
Tess, Optimize, Sunoil, Biogrease, Biomon
Tribology of mechanical components: Gears
Aerohums, Selena
© IK4-TEKNIKER 2016
Testing components efficiency
Studies: Lead free materials, coatings
Actions:Testing materials, lubricants
Interest:
• Durability,
• noise reduction,
• Reduce contact temperature
• Reduction of environmental impact
Testing durability of Journal bearings.
Novel Product design, materials & Maintenance
BeLeadFree bearings, Ecobearings, GraphnologyCleanengine
Tribology of mechanical components: Journal Bearings
Journal Bearing Simulation
Thrust Washer Test Configuration
CuPb22Sn disc against 50CrV4 ring
0
20
40
60
80
100
1 301 601 901 1201 1501 1801 2101 2401 2701 3001 3301 3601 3901
Temperature (ºC)
© IK4-TEKNIKER 2016
Testing components efficiency
Studies: materials, coatings
Actions:Testing materials, lubricants
Modelling life with oil sensors
and vibrations
Interest:
• Durability, pitting, micropitting
• Vibration & noise reduction,
• Reduction of contact temperature
Testing durability of Rolling bearings.
Novel Product design, materials & Maintenance
Biomon, Eurobearing, Refine, Twin Control
Tribology of mechanical components: Rolling Bearings
© IK4-TEKNIKER 2016
High Temperature resistance Materials Increase durability
Type of failures:
• Thermal fatigue
• Mechanical fatigue
• Die soldering
• Abrasion, adhesion
• Stress corrosion
▪Results: Prediction of lifetime▪ Type moulds: HPDC, PIM
▪Current activites: Technological services, research
projects
Solutions to:
• predict lifetime of materials at high temperature
Prediction of lifetime of materials at high temperature
High temperature tribology: Moulds wear
Alepre
© IK4-TEKNIKER 2016
Light weight Materials Plasma Electroxidation Coatings for Al, Mg, Ti
Need: Weight reduction.
Material: Al, Ti, Mg. Coating: PEO
Actions:
•Samples preparation and coating application
•Coating in components.
•Corrosion resistance
•Tribological tests cylinder liner piston rings
•Tribocorrosion tests.
Results: Benchmarking tribological solutions.
Use transport: for enhancing properties of light alloys
Substitution of cast iron by Aluminio +PEO
Al2O3
NADIA, NANOMAGCLEANENGINE, EREBIO
High temperature tribology: Engine Components
AUMORE, MOTORGARBI, REMTRAL, EQUIMOTOR
© IK4-TEKNIKER 2016
Pistons Coatings, biolubricants, biofuels
Need: Reduction of scuffing.
Coatings: DLC, HVOF, CrN and TiN
.Actions:
•Design of testing configuration
•Lubrication oil, oil/fuel (2 stroke engines).
•Corrosion resistance
•Tribological tests cylinder liner piston rings
•Tribological tests piston skirt/cylinder liner
•Tribocorrosion tests.
Results: Benchmarking tribological solutions.
Use: reduction of emisions, Lubricants compatible
with biofuels
Clean engines (low emission, biofuels, biolubricants)
NADIA, NANOMAGCLEANENGINE, EREBIO
High temperature tribology: Engine Components
AUMORE, MOTORGARBI, REMTRAL, EQUIMOTOR
© IK4-TEKNIKER 2016
Testing components efficiency
Studies: materials, coatings, texturing
Actions:Testing materials, lubricants
Modelling life with oil sensors
and vibrations
Interest:
• Durability, los friction, leakage
• Vibration & noise reduction,
• Reduction of contact temperature
• ISO 7986: 1997.
Testing durability of Seals and Elastomers
Novel Product design, manufacturing & Maintenance
Stokes, Isselub,
Tribology of soft materials: Seals and elastomers
Load
Plunger
holders
Rubber
sample
Oil bath
Movement direction
Rod
50X 100X 200X
3D Flex
© IK4-TEKNIKER 2016
Testing safety
Studies: materials, coatings, texturing
Actions:Testing materials, coatings
Stick Slip, slippery, in water, oil,
Antimicrobial, cleaning agents
Interest:
• Durability
• Noise, stick slip
• Slippery, Comfort
• Antimicrobial
Testing durability of Floorings.
Novel Product design, manufacturing & Maintenance
SafeSlip
Tribology of soft materials: Antislip Floorings
Without biocide With biocide
© IK4-TEKNIKER 2016
Testing Comfort, safety
Studies: materials, coatings, texturing
Actions:Testing materials, coatings
Tactile, stick slip, tearing, strength,
Antimicrobial, cleaning agents
Interest:
• Durability
• Tactile, stick slip
• Comfort
• Antimicrobial
Testing durability and comfort of Textiles
Novel Product materials design & quality
2B Funtex
Tribology of soft materials: Textiles
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0 50 100 150 200 250 300 350 400 450
Fric
. Co
ef.
(µ
)
Time (s)
Comparative Dry-Wet Conditions
Cotton 100% Dry
Polyester 100% Dry
50%Cotton-50%Polyester Dry
Cotton 100% Wet
Polyester 100% Wet
50%Cotton-50%Polyester Wet
0
5
10
15
20
25
30
35
0 20 40 60 80 100 120 140 160 180
Load
(N
)
Extension (mm)
Tear Tests
100% Cotton across warp
100% Cotton across weft
Polyester 100% across warp
Polyester 100% across weft
50% Cotton + 50% Polyester across warp
50% Cotton + 50% Polyester across weft
Emaitek
© IK4-TEKNIKER 2016
Testing eco-efficiency
Studies: materials, coatings, lubricants
Actions: Testing efficiency, torque,
Lubricant properties, ecotoxicity,
Biodegradability, lifecycle assessment
Interest:
• Increase efficiency
• Reduce torque
• Reduce of working temperature
• Minimal quantity of fluid
• Lifecycle environmental assessment
• Low ecotoxicity (OECD 201, 202)
• Biodegradability after use (OECD 301F)
Testing efficiency of sunflower based cutting fluids
Improvement of process (tool, Lubrication, ecology)
Tribolubrication: Cutting and forming applications
ROTATIONAL DRAWING
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
0,00 0,05 0,10 0,15 0,20 0,25
TIME (sec)
TO
RQ
UE
(N
m)
100 98
0
20
40
60
80
100
120
Mineral (REF) VOSOLUB
% R
ela
tiv
e e
ffic
ien
cy
Tapping Cutting (Titanium)
FlankWear
© IK4-TEKNIKER 2016
Ecotribological solutions
Studies: HOSO base oils
and glycol free fire resistance
hydraulic oils
Actions: Testing friction, Wear,
extreme pressure, biodegradability,
ecotoxicity
Interest:
• Durability
• Low friction
• High extreme pressure
• Biodegradable after use
• Non ecotoxic
Testing durability in hydraulic fluids (aerogenerators, agricultural machinery, hydraulic equipments)
Novel ecofriendly lubricants design & maintenance
Biovesin
Tribology of ecolubricants: Bearings and Gears
Extreme pressure test results 1
Lubricant Seizure load
RAGH 126
BIOGIR-06 160
2
Extreme pressureFire resistant
Biodegradable
© IK4-TEKNIKER 2016
How Tribology will help new materials to survive in different environments and systems
Friction related Phenomena
Tribology, Tribolubrication, Tribocorrosion, Tribochemistry, Tribodesorption, Triboreactivity, Tribolayer,
Tribomechanisms, Biotribology, Tribobioadhesion, tribobiocorrosion (tribobioadhesion+tribocorrosion)
Damage Mechanisms (chemical & mechanical Wear) and friction consequences
Pitting, Micropitting, Scuffing, fretting, fading, stick-slip, die soldering, abrasión, adhesion, corrosion,
stress corrosion, thermal fatigue, drag friction, efficiency, noise, vibration, squeal, slippery, tactility,..
comfort
1. A huge range of testing equipments are available to simulate different environments
2. The knowledge about the working conditions and reproduction of failure mechanism at laboratory
will make possible to reproduce a wider number of tribological systems.
3. It is necessary to make a step forward towards modelling the extrapolation of the laboratory testing
to the real system and the generation of new standards.
4. Tribology is the tool to implement low carbon footprint materials into energy and resource efficient
real systems
CONCLUSIONS
© IK4-TEKNIKER 2016
• Thanks for your interest
• Organization of EuroNanoForum and EU Commission
• Financing Agencies at EU, National and Regional level
• Collaborators in the EU, National and Industrial Projects
• Colleagues from IK4-TEKNIKER that participated in the results
ACKNOWLEDGEMENTS
© IK4-TEKNIKER 2016