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7/30/2019 TRIBOLOGY..Assignment
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Beant college of engineering & technology
gurdaspur
INDUSTRIAL TRIBOLOGY
Assignment
INDUSTRIAL TRIBOLOGY
DEFINITION:
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The science offriction, lubrication and wearis called tribology.
FRICTIONFriction is theforce resisting the relative motion of solid surfaces, fluid layers, and
material elements sliding against each other. There are several types of friction:
Dry friction resists relative lateral motion of two solid surfaces in contact. Dry
friction is subdivided into static friction ("stiction") between non-moving surfaces,
and kinetic friction between moving surfaces.
Fluid friction describes the friction between layers within a viscous fluid that aremoving relative to each other.
Lubricated friction is a case of fluid friction where a fluid separates two solid
surfaces.
Skin friction is a component ofdrag, the force resisting the motion of a solid body
through a fluid.
Internal friction is the force resisting motion between the elements making up a
solid material while it undergoes deformation.
When surfaces in contact move relative to each other, the friction between the two
surfaces converts kinetic energyinto heat. This property can have dramatic
consequences, as illustrated by the use of friction created by rubbing pieces of wood
together to start a fire. Kinetic energy is converted to heat whenever motion with friction
occurs, for example when aviscousfluid is stirred. Another important consequence of
many types of friction can bewear, which may lead to performance degradation and/ordamage to components. Friction is a component of the science oftribology.
Friction is not itself a fundamental force but arises from fundamental electromagnetic
forces between the charged particles constituting the two contacting surfaces. The
http://en.wikipedia.org/wiki/Frictionhttp://en.wikipedia.org/wiki/Wearhttp://en.wikipedia.org/wiki/Tribologyhttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Surfacehttp://en.wikipedia.org/wiki/Stictionhttp://en.wikipedia.org/wiki/Viscoushttp://en.wikipedia.org/wiki/Drag_(physics)http://en.wikipedia.org/wiki/Deformation_(mechanics)http://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Viscous_flowhttp://en.wikipedia.org/wiki/Viscous_flowhttp://en.wikipedia.org/wiki/Viscous_flowhttp://en.wikipedia.org/wiki/Wearhttp://en.wikipedia.org/wiki/Wearhttp://en.wikipedia.org/wiki/Wearhttp://en.wikipedia.org/wiki/Tribologyhttp://en.wikipedia.org/wiki/Fundamental_forcehttp://en.wikipedia.org/wiki/Electromagnetic_forcehttp://en.wikipedia.org/wiki/Electromagnetic_forcehttp://en.wikipedia.org/wiki/Frictionhttp://en.wikipedia.org/wiki/Wearhttp://en.wikipedia.org/wiki/Tribologyhttp://en.wikipedia.org/wiki/Forcehttp://en.wikipedia.org/wiki/Surfacehttp://en.wikipedia.org/wiki/Stictionhttp://en.wikipedia.org/wiki/Viscoushttp://en.wikipedia.org/wiki/Drag_(physics)http://en.wikipedia.org/wiki/Deformation_(mechanics)http://en.wikipedia.org/wiki/Kinetic_energyhttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Viscous_flowhttp://en.wikipedia.org/wiki/Wearhttp://en.wikipedia.org/wiki/Tribologyhttp://en.wikipedia.org/wiki/Fundamental_forcehttp://en.wikipedia.org/wiki/Electromagnetic_forcehttp://en.wikipedia.org/wiki/Electromagnetic_force7/30/2019 TRIBOLOGY..Assignment
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complexity of these interactions makes the calculation of friction from first
principles impossible and necessitates the use ofempirical methods for analysis and the
development of theory.
LUBRICATION
is the process, or technique employed to reduce wear of one or both surfaces in
close proximity, and moving relative to each other, by interposing a substance
called lubricant between the surfaces to carry or to help carry the load (pressure
generated) between the opposing surfaces. The interposed lubricant film can be a
solid, (e.g. graphite, MoS2) a solid/liquid dispersion, a liquid, a liquid-liquid
dispersion (a grease) or, exceptionally, a gas.
In the most common case the applied load is carried by pressure generated within
the fluid due to the frictional viscous resistance to motion of the lubricating fluid
between the surfaces.
Lubrication can also describe the phenomenon such reduction of wear occurs
without human intervention (hydroplaning on a road).
The science offriction, lubrication and wearis called tribology.
Adequate lubrication allows smooth continuous operation of equipment, with only
mild wear, and without excessive stresses or seizures at bearings. When
lubrication breaks down, metal or other components can rub destructively over
each other, causing destructive damage, heat, and failure.
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THE REGIMES OF LUBRICATION-
As the load increases on the contacting surfaces three distinct situations can be
observed with respect to the mode of lubrication, which are called regimes of
lubrication:
Fluid film lubrication is the lubrication regime in which through viscous
forces the load is fully supported by the lubricant within the space or gap
between the parts in motion relative to one another (the lubricated
conjunction) and solidsolid contact is avoided. [2]
Hydrostatic lubrication is when an external pressure is applied to
the lubricant in the bearing, to maintain the fluid lubricant film where itwould otherwise be squeezed out.
Hydrodynamic lubrication is where the motion of the contacting
surfaces, and the exact design of the bearing is used to pump lubricant
around the bearing to maintain the lubricating film. This design of bearing
may wear when started, stopped or reversed, as the lubricant film breaks
down.
Elastohydrodynamic lubrication: The opposing surfaces are separated,
but there occurs some interaction between the raised solid features
called asperities, and there is an elastic deformation on the contacting
surface enlarging the load-bearing area whereby the viscous resistance of the
lubricant becomes capable of supporting the load.
Boundary lubrication (also called boundary film lubrication): The bodies
come into closer contact at their asperities; the heat developed by the localpressures causes a condition which is called stick-slip and some asperities
break off. At the elevated temperature and pressure conditions chemically
reactive constituents of the lubricant react with the contact surface forming a
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highly resistant tenacious layer, or film on the moving solid surfaces (boundary
film) which is capable of supporting the load and major wear or breakdown is
avoided. Boundary lubrication is also defined as that regime in which the load
is carried by the surface asperities rather than by the lubricant.
WEAR
In materials science, wearis erosion or sideways displacement of material from
its "derivative" and original position on a solidsurfaceperformed by the action of
another surface.
Wear is related to interactions between surfaces and more specifically the
removal and deformation of material on a surface as a result of mechanical action
of the opposite surface. The need for relative motion between two surfaces and
initial mechanical contact between asperities is an important distinction between
mechanical wear compared to other processes with similar outcomes.
The definition of wear may include loss of dimension from plastic deformation if it
is originated at the interface between two sliding surfaces.
However, plastic deformation such as yield stress is excluded from the wear
definition if it doesn't incorporates a relative sliding motion and contact againstanother surface despite the possibility for material removal, because it then lacks
the relative sliding action of another surface.
Impact wear is in reality a short sliding motion where two solid bodies interact at
an exceptional short time interval. Previously due to the fast execution, the
contact found in impact wear was referred to as an impulse contact by the
nomenclature. Impulse can be described as a mathematical model of a
synthesized average on the energy transport between two travelling solids in
opposite converging contact.
Cavitation wear is a form of wear where the erosive medium or counter-body is a
fluid.
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Corrosion may be included in wear phenomenon, but the damage is amplified and
performed by chemical reactions rather than mechanical action.
Wear can also be defined as a process where interaction between two surfaces or
bounding faces of solids within the working environment results in dimensionalloss of one solid, with or without any actual decoupling and loss of material.
Aspects of the working environment which affect wear include loads and features
such as unidirectional sliding, reciprocating, rolling, and impact loads, speed,
temperature, but also different types of counter-bodies such as
solid, liquid orgas and type of contact ranging between single phase or
multiphase, in which the last multiphase may combine liquid with solid particles
and gas bubbles.
STAGES OF WEAR
Under normal mechanical and practical procedures, the wear-rate normally
changes through three different stages(ref.4):
Primary stage or early run-in period, where surfaces adapt to each otherand the wear-rate might vary between high and low.
Secondary stage or mid-age process, where a steady rate of ageing is in
motion. Most of the components operational life is comprised in this stage.
Tertiary stage or old-age period, where the components are subjected to
rapid failure due to a high rate of ageing.
The secondary stage is shortened with increasing severity of environmental
conditions such as higher temperatures, strain rates, stress and sliding velocities
etc.
Note that, wear rate is strongly influenced by the operating conditions.
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Specifically, normal loads and sliding speeds play a pivotal role in determining
wear rate. In addition, tribo-chemical reaction is also important in order to
understand the wear behavior. Different oxide layers are developed during the
sliding motion. The layers are originated from complex interaction among surface,
lubricants, and environmental molecules. In general, a single plot, namely wear
map. Demonstrating wear rate under different loading condition is used for
operation. This graph also represents dominating wear modes under different
loading conditions.
In explicit wear tests simulating industrial conditions between metallic surfaces,
there are no clear chronological distinction between different wear-stages due to
big overlaps and symbiotic relations between various friction
mechanisms. Surface engineering and treatments are used to minimize wear and
extend the components working life.
TYPES
The study of the processes of wear is part of the discipline of tribology. The
complex nature of wear has delayed its investigations and resulted in isolated
studies towards specific wear mechanisms or processes. Some commonly
referred to wear mechanisms (or processes) include:
1. Adhesive wear
2. Abrasive wear
3. Surface fatigue
4. Fretting wear
5. Erosive wear
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Adhesive wear
Adhesive wear can be found between surfaces during frictional contact and
generally refers to unwanted displacement and attachment of wear debris and
material compounds from one surface to another. Two separate mechanisms
operate between the surfaces.
Abrasive wear
Abrasive wear occurs when a hard rough surface slides across a softer
surface. ASTM International (formerly American Society for Testing and Materials)
defines it as the loss of material due to hard particles or hard protuberances that
are forced against and move along a solid surface.
Abrasive wear is commonly classified according to the type of contact and the
contact environment. The type of contact determines the mode of abrasive wear.
The two modes of abrasive wear are known as two-body and three-body abrasive
wear. Two-body wear occurs when the grits or hard particles remove material
from the opposite surface. The common analogy is that of material being removed
or displaced by a cutting or plowing operation. Three-body wear occurs when the
particles are not constrained, and are free to roll and slide down a surface. The
contact environment determines whether the wear is classified as open or closed.
An open contact environment occurs when the surfaces are sufficiently displaced
to be independent of one another
Deep 'groove' like surface indicates abrasive wear over cast iron (yellow arrow
indicate sliding direction)
There are a number of factors which influence abrasive wear and hence the
manner of material removal. Several different mechanisms have been proposed
to describe the manner in which the material is removed. Three commonly
identified mechanisms of abrasive wear are:
1. Plowing
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2. Cutting
3. Fragmentation
Plowing occurs when material is displaced to the side, away from the wearparticles, resulting in the formation of grooves that do not involve direct material
removal. The displaced material forms ridges adjacent to grooves, which may be
removed by subsequent passage of abrasive particles. Cutting occurs when
material is separated from the surface in the form of primary debris, or microchips,
with little or no material displaced to the sides of the grooves. This mechanism
closely resembles conventional machining. Fragmentation occurs when material
is separated from a surface by a cutting process and the indenting abrasive
causes localized fracture of the wear material. These cracks then freely propagate
locally around the wear groove, resulting in additional material removal by
spalling.
Abrasive wear can be measured as loss of mass by the Taber Abrasion Test
according to ISO 9352 or ASTM D 1044.
Surface fatigue
Surface fatigue is a process by which the surface of a material is weakened by
cyclic loading, which is one type of general material fatigue. Fatigue wear is
produced when the wear particles are detached by cyclic crack growth of
microcracks on the surface. These microcracks are either superficial cracks or
subsurface cracks.
Fretting wear
Fretting wear is the repeated cyclical rubbing between two surfaces, which is
known as fretting, over a period of time which will remove material from one or
both surfaces in contact. It occurs typically in bearings, although most bearings
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have their surfaces hardened to resist the problem. Another problem occurs when
cracks in either surface are created, known as fretting fatigue. It is the more
serious of the two phenomena because it can lead to catastrophic failure of the
bearing. An associated problem occurs when the small particles removed by wear
are oxidised in air. The oxides are usually harder than the underlying metal, so
wear accelerates as the harder particles abrade the metal surfaces further.
Fretting corrosion acts in the same way, especially when water is present.
Unprotected bearings on large structures like bridges can suffer serious
degradation in behavior, especially when salt is used during winter to deice the
highways carried by the bridges. The problem of fretting corrosion was involved in
the Silver Bridge tragedy and the Mianus River Bridge accident.
Erosive wear
Erosive wear can be described as an extremely short sliding motion and is
executed within a short time interval. Erosive wear is caused by the impact of
particles of solid or liquid against the surface of an object. The impacting particles
gradually remove material from the surface through repeated deformations and
cutting actions. It is a widely encountered mechanism in industry. A common
example is the erosive wear associated with the movement of slurries throughpiping and pumping equipment.
The rate of erosive wear is dependent upon a number of factors. The material
characteristics of the particles, such as their shape, hardness, impact velocity and
impingement angle are primary factors along with the properties of the surface
being eroded. The impingement angle is one of the most important factors and is
widely recognized in literature. For ductile materials the maximum wear rate is
found when the impingement angle is approximately 30, whilst for non ductile
materials the maximum wear rate occurs when the impingement angle is normal
to the surface.
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TYPES OF MOTION
SLIDING (MOTION)
Sliding is a type of frictional motion between two surfaces in contact. This can be
contrasted to rolling motion. Both types of motion may occur in bearings.
The relative motion or tendency toward such motion between two surfaces is resisted
by friction. Friction may damage or 'wear' the surfaces in contact. However, wear can be
reduced by lubrication. The science and technology of friction, lubrication, and wear is
known astribology
Sliding may occur between two objects of arbitrary shape, whereas rolling friction is the
frictional force associated with the rotational movement of a somewhat disclike or other
circular object along a surface. Generally the frictional force ofrolling friction is less than
that associated with slidingkinetic friction.[1]Typical values for the coefficient of rolling
friction are less than that of sliding friction.[2]
Correspondingly sliding friction typicallyproduces greater sound and thermal bi-products. One of the most common examples of
sliding friction is the movement ofbrakingmotor vehicletires on a roadway, a process
which generates considerable heat andsound, and is typically taken into account in
assessing the magnitude of roadwaynoise pollution.
ROLLING (MOTION)
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is a type of motion that combines rotation (commonly, of an axially
symmetric object) and translation of that object with respect to a surface (either
one or the other moves), such that, if ideal conditions exist, the two are in contact
with each other without sliding.
Rolling is achieved by a rotational speed at the line or point of contact which is
equal to the translational speed. When no sliding takes place the rolling motion is
referred to as 'pure rolling'. In practice, due to small deformations at the contact
area, some sliding does occur. Nevertheless, rolling resistance is much lower
than sliding friction, and thus, rolling objects, typically require much less energyto
be moved than sliding ones. As a result, such objects will more easily move, if
they experience a force with a component along the surface, for instance gravity
on a tilted surface; wind; pushing; pulling; an engine. Unlike most axially
symmetrical objects, the rolling motion of a cone is such that while rolling on a flat
surface, its center of gravity performs a circular motion, rather than a linearone.
Rolling objects are not necessarily axially-symmetrical. Two well known non-
axially-symmetrical rollers are the Reuleaux triangle and theMeissner bodies.
Objects with corners, such as dice, roll by successive rotations about the edge or
corner which is in contact with the surface.
One of the most practical applications of rolling objects is the use ofRolling-
element bearings, such asball bearings, in rotating devices. Made of a smooth
metal substance, the rolling elements are usually encased between two rings that
can rotate independently of each other. In most mechanisms, the inner ring is
attached to a stationary shaft (or axle). Thus, while the inner ring is stationary, the
outer ring is free to move with very little friction. This is the basis for which almost
all motors (such as those found in ceiling fans, cars, drills, etc.) rely on to operate.
The amount of friction on the mechanism's parts depends on the quality of the ball
bearings and how much lubrication is in the mechanism.
Rolling objects are also frequently used as toolsfortransportation. One of the
most basic ways is by placing a (usually flat) object on a series of lined-up rollers,
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orwheels. The object on the wheels can be moved along them in a straight line,
as long as the wheels are continuously replaced in the front (see history of
bearings). This method of primitive transportation is efficient when no other
machinery is available. Today, the most practical application of objects on wheels
are cars, trains, and other human transportation vehicles.
The velocity of a particle in the rolling object is given by: , where is
the distance between the particle and the rolling object's contact point (or line),
and is the rolling object's angular velocity.
Deformation
In materials science, deformation is a change in the shape or size of an object
due to an applied force (the deformation energy in this case is transferred through
work) or a change in temperature (the deformation energy in this case is
transferred through heat). The first case can be a result oftensile (pulling)
forces, compressive (pushing) forces, shear, bending ortorsion (twisting). In the
second case, the most significant factor, which is determined by the temperature,
is the mobility of the structural defects such as grain boundaries, point vacancies,
line and screw dislocations, stacking faults and twins in both crystalline and non-
crystalline solids. The movement or displacement of such mobile defects is
thermally activated, and thus limited by the rate of atomic diffusion. Deformation is
often described as strain.[1][2]
As deformation occurs, internal inter-molecular forces arise that oppose the
applied force. If the applied force is not too large these forces may be sufficient to
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completely resist the applied force, allowing the object to assume a new
equilibrium state and to return to its original state when the load is removed. A
larger applied force may lead to a permanent deformation of the object or even to
its structural failure.
In the figure it can be seen that the compressive loading (indicated by the arrow)
has caused deformation in the cylinderso that the original shape (dashed lines)
has changed (deformed) into one with bulging sides. The sides bulge because the
material, although strong enough to not crack or otherwise fail, is not strong
enough to support the load without change, thus the material is forced out
laterally. Internal forces (in this case at right angles to the deformation) resist the
applied load.
TYPES OF DEFORMATION
Depending on the type of material, size and geometry of the object, and the forces
applied, various types of deformation may result. The image to the right shows the
engineering stress vs. strain diagram for a typical ductile material such as steel.
Different deformation modes may occur under different conditions, as can be
depicted using a deformation mechanism map.
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Typical stress vs. strain diagram with the various stages of deformation.
Elastic deformation
This type of deformation is reversible. Once the forces are no longer applied, the
object returns to its original shape. Elastomersand shape memory metals such
as Nitinol exhibit large elastic deformation ranges, as doesrubber. However
elasticity is nonlinear in these materials. Normal metals, ceramics and most
crystals show linear elasticity and a smaller elastic range.
Linear elastic deformation is governed by Hooke's law, which states:
Where is the applied stress, is a material constant called Young's
modulus, and is the resulting strain. This relationship only applies in the
elastic range and indicates that the slope of the stress vs. strain curve can be
used to find Young's modulus. Engineers often use this calculation in tensile
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tests. The elastic range ends when the material reaches its yield strength. At
this point plastic deformation begins.
Note that not all elastic materials undergo linear elastic deformation; some,
such as concrete, gray cast iron, and many polymers, respond nonlinearly. Forthese materials Hooke's law is inapplicable.
Plastic deformation
This type of deformation is irreversible. However, an object in the plastic
deformation range will first have undergone elastic deformation, which is
reversible, so the object will return part way to its original shape.Soft thermoplastics have a rather large plastic deformation range as do ductile
metals such as copper,silver, and gold. Steel does, too, but not cast iron.
Hard thermosetting plastics, rubber, crystals, and ceramics have minimal
plastic deformation ranges. One material with a large plastic deformation
range is wet chewing gum, which can be stretched dozens of times its original
length.
Under tensile stress plastic deformation is characterized by a strainhardening region and a necking region and finally, fracture (also called
rupture). During strain hardening the material becomes stronger through the
movement ofatomic dislocations. The necking phase is indicated by a
reduction in cross-sectional area of the specimen. Necking begins after the
ultimate strength is reached. During necking, the material can no longer
withstand the maximum stress and the strain in the specimen rapidly
increases. Plastic deformation ends with the fracture of the material.
Metal fatigue
Another deformation mechanism is metal fatigue, which occurs primarily
in ductile metals. It was originally thought that a material deformed only within
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the elastic range returned completely to its original state once the forces were
removed. However, faults are introduced at the molecular level with each
deformation. After many deformations, cracks will begin to appear, followed
soon after by a fracture, with no apparent plastic deformation in between.
Depending on the material, shape, and how close to the elastic limit it is
deformed, failure may require thousands, millions, billions, or trillions of
deformations.
Metal fatigue has been a major cause of aircraft failure, such as the De
Havilland Comet accidents, especially before the process was well
understood. There are two ways to determine when a part is in danger of
metal fatigue; either predict when failure will occur due to the
material/force/shape/iteration combination, and replace the vulnerable
materials before this occurs, or perform inspections to detect the microscopic
cracks and perform replacement once they occur. Selection of materials not
likely to suffer from metal fatigue during the life of the product is the best
solution, but not always possible. Avoiding shapes with sharp corners limits
metal fatigue by reducing stress concentrations, but does not eliminate it.
Compressive failure
Usually, compressive stress applied to bars, columns, etc. leads to shortening.
Loading a structural element or a specimen will increase the compressive
stress until the reach ofcompressive strength. According to the properties of
the material, failure will occur as yield for materials with ductile behavior
(most metals, some soils and plastics) or as rupture for brittle behavior
(geomaterials,cast iron, glass, etc.).
In long, slender structural elements such as columns ortruss bars an
increase of compressive force Fleads to structural failure due to bucklingat
lower stress than the compressive strength.
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Fracture
Diagram of astress-strain curve, showing the relationship between stress (force applied) and
strain (deformation) of a ductile metal.
This type of deformation is also irreversible. A break occurs after the material
has reached the end of the elastic, and then plastic, deformation ranges. At
this point forces accumulate until they are sufficient to cause a fracture. All
materials will eventually fracture, if sufficient forces are applied.
Misconceptions
A popular misconception is that all materials that bend are "weak" and those
that don't are "strong." In reality, many materials that undergo large elastic and
plastic deformations, such as steel, are able to absorb stresses that would
cause brittle materials, such as glass, with minimal plastic deformation ranges,
to break.
Surface energy
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Contact anglemeasurements can be used to determine the surface energy of a material. Here, a
drop of water on glass.
SURFACE ENERGYquantifies the disruption of intermolecular bonds thatoccur when a surface is created. In the physics ofsolids, surfaces must be intrinsically
less energetically favorable than the bulk of a material (the molecules on the surface
have more energy compared with the molecules in the bulk of the material), otherwise
there would be a driving force for surfaces to be created, removing the bulk of the
material (see sublimation). The surface energy may therefore be defined as the excess
energy at the surface of a material compared to the bulk.
For a liquid, thesurface tension (force per unit length) and the surface energy density are
identical. Water has a surface energy density of 0.072 J/m2and a surface tension of 0.072
N/m; the units are equivalent.
Cutting a solid body into pieces disrupts its bonds, and therefore consumes energy. If the
cutting is done reversibly (see reversible), then conservation of energy means that the
energy consumed by the cutting process will be equal to the energy inherent in the two
new surfaces created. The unit surface energy of a material would therefore be half of its
energy ofcohesion, all other things being equal; in practice, this is true only for a surface
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freshly prepared in vacuum. Surfaces often change their form away from the simple
"cleaved bond" model just implied above. They are found to be highly dynamic regions,
which readily rearrange or react, so that energy is often reduced by such processes
as passivation oradsorption.
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