The New Methods For Scuffing and Pitting Investigation of Coated Materials For Heavy Loaded, Lubricated Elements
The New Methods For Scuffing and Pitting Investigation of Coated Materials For Heavy Loaded, Lubricated Elements
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pressed into the cracks at a very high pressure (elastohydrodynamic lubrication), making them
propagate. Finally, cyclic stress results in breaking a piece of material off the surface. Examples
of a gear and a race worn due to pitting (Michalczewski et al., 2010) are presented in Fig. 2.
(a)
(b)
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For the purpose of the tribological research in the areas mentioned above, two tribological
devices have been developed:
The T-02U Universal Four-Ball Testing Machine,
The T-12U Universal Back-to-back Gear Test Rig.
The set of methods and devices intended for the comprehensive tribological evaluation of
PVD/CVD coatings is presented in Fig. 3.
MODEL TESTS
COMPONENT TESTS
SCUFFING
PITTING
SCUFFING
PITTING
T-02U
T-12U
Fig. 3. The tribological methods and devices developed intended for comprehensive
tribological evaluation of elements covered with PCD/CVD coatings
By means of this set, low-friction and antiwear PVD/CVD coatings can be evaluated from
micro to macroscale in model and component tests (Antonov et al., 2009).
Using new devices, five test methods, giving the possibility of comprehensive testing of
various low-friction and antiwear PVD/CVD coatings intended for machine elements, were
developed. They are as follows:
The model method for the evaluation of scuffing in the four-ball tribosystem,
The model method for the evaluation of scuffing in the cone-three balls tribosystem,
The model method for the evaluation of pitting wear in the cone-three balls tribosystem,
The component gear method for the evaluation of scuffing resistance of gears,
The component gear method for the evaluation of pitting wear of gears.
The new test methods and the new devices for the experimental evaluation of friction and
wear of low-friction and antiwear PVD/CVD coatings are described below.
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b)
Fig. 4. Model tribosystems for testing scuffing: a) four-ball tribosystem: 1- top ball, 2- lower
balls, 3- ball chuck, 4 ball pot, b) cone-three balls tribosystem; 1 top cone, 2 bottom
balls, 3 ball chuck, 4-ball pot
The three stationary, bottom balls (2), having a diameter of 0.5 in., are fixed in the ball pot
(4) and pressed against the top ball or cone (1) at the continuously increasing load P. The top
ball/cone is fixed in the ball chuck (3) and rotates at the constant speed n. The tribosystem is
immersed in the tested lubricant. During the run the friction torque is observed until seizure
occurs.
The test conditions are as follows: rotational speed: 500 rpm, speed of continuous load
increase: 409 N/s, initial applied load: 0 N, maximum load: 7200 100 N.
The methods are described in detail in works (Szczerek & Tuszynski, 2002) and patented
(Polish Patent No. 179123 - B1 G01N 33/30). A friction torque curve (Mt) obtained at the
continuously increasing load (P) is shown in Fig. 5.
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Applied load, P
Friction torque, Mt
309
seizure
Mt = 10 Nm
Poz
Mt
Pt
1
scuffing initiation
Time
Fig. 5. Simplified friction torque curve (Mt) obtained at continuously increasing load (P);
1 scuffing initiation, 1-2 scuffing propagation, 2 seizure (exceeding 10 Nm friction torque)
Scuffing initiation occurs at the time of a sudden increase in the friction torque point 1. The
load at this moment is called the scuffing load and denoted Pt.
According to the new test method, the load still increases (over a value of Pt) until seizure
occurs (i.e. friction torque exceeds 10 N m point 2). The load at this moment will be called
the seizure load and denoted Poz. If 10 Nm is not reached, maximum load (c.a. 7200 N) is
considered to be the seizure load (although in such a case there is no seizure). For every
tested lubricant the so-called limiting pressure of seizure (denoted poz) should be calculated.
This value reflects the lubricant behaviour under scuffing conditions and is equal to the
nominal pressure exerted on the wear scar surface at the moment of seizure or at the end of
the run (when seizure has not appeared). The limiting pressure of seizure is calculated from
the equation (1):
P
poz = 0.52 oz
d2
(1)
where:
poz limiting pressure of seizure, N/mm2,
Poz seizure load [N],
d average wear scar diameter measured on the stationary balls, mm.
The 0.52 coefficient results from the force distribution in the four-ball tribosystem. The
higher poz value, the better action of the tested lubricant under scuffing conditions is.
The developed test methods were successfully used for testing the scuffing resistance of
components with thin hard coatings (thickness of 2 m) deposited by PVD/CVD method.
The example of their application (Michalczewski et al., 2010) is presented in Fig. 6.
Wear scars images on lower balls from scuffing tests for steel-steel and CrN-CrN
tribosystems are presented in Fig. 7.
The developed test methods have the resolution, not achieved by the other methods, good
enough to differentiate between coatings, engineering materials and lubricants (Piekoszewski,
Szczerek & Tuszynski, 2001). What is more, they are fast and inexpensive. So, these test
methods can be effectively used to select the optimum substrate-coating-lubricant
combinations best suited for highly loaded machine components (Michalczewski et al., 2009a).
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a)
8000
6000
4000
2000
CrN-CrN
TiN-TiN
WC/C-WC/C
Steel-steel
0
o
se
Ba
il +
EP
o
se
Ba
il +
AW
M
r al
ine
oil
se
ba
b)
8000
7000
6000
5000
4000
3000
WC/C
Carburized steel
Nitrided steel
Tool steel
Bearing steel
2000
1000
0
o
se
Ba
il +
EP
o
se
Ba
il +
M
AW
b
r al
ine
il
eo
as
Fig. 6. Results from scuffing tests for lubricants, engineering materials and thin hard
coatings: a) modified four-ball scuffing test, b) cone-three balls scuffing test
(a)
(b)
Fig. 7. Wear scars images on lower balls from scuffing tests for: a) steel-steel, b) CrN-CrN
(four ball test, mineral base oil without lubricating additives)
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2.2 Model method for evaluation of pitting wear in cone-three balls tribosystem
The cone-three balls test method is generally based on IP 300 standard (Rolling contact
fatigue tests for fluids in a modified four-ball machine). The main change is the geometry of
the contact of the rolling elements. The upper ball was replaced with a special cone
(Michalczewski & Piekoszewski, 2006). The cone can be made of any material. The conethree balls tribosystem is presented in Fig. 8.
b)
a)
L10 [min.]
500
400
300
200
100
0
100Cr6
WC/C
MoS2/Ti
MoS2
TiN
CrN
Fig. 9. Results from pitting tests for 100Cr6 steel covered with thin, hard coating
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The SEM images of wear on the test cone from pitting tests for 100Cr6 steel covered with
WC/C coating are presented in Fig. 10.
(a)
(b)
(c)
Fig. 10. The pitting wear on the test cone: a) upper view, b) cross-section, c) enlargement of
selected fragment (WC/C coated cone, RL-144/4 mineral oil)
The results indicate beneficial impact of low friction coatings on pitting wear (e.g. MoS2/Ti
coating).
The presented method for testing pitting in cone-three balls tribosystem can be applied to
testing fatigue wear of various materials, surface coatings as well as various lubricants. In
comparison to other existing methods the new method gives better resolution and is timeand cost-effective.
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(a)
(b)
Fig. 11. T-02U Universal Four-Ball Testing Machine: a) photograph, b) computer screen
during data acquisition
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A very wide range of lubricants can be tested using the T-02U Machine, e.g.: gear oils,
hydraulic-gear oils, motor oils, eco-lubricants, non-toxic lubricants, new EP additives,
cutting fluids, and greases. Many test methods described in international and national
standards can be performed - ISO 20623, ASTM D 2783, D 2596, D 4172, D 2266, D 5183, DIN
51350, IP 239, IP 300, PN-76/C-04147. They concern the determination of the influence of the
tested lubricants on scuffing, pitting, friction coefficient, and sliding wear, at ambient and
elevated temperatures.
3. Component methods and T-12U Universal Back-to-back Gear Test Rig for
evaluation of scuffing resistance and rolling contact fatigue of PVD/CVD
coated gears
In research where high reliability is at stake, there is a tendency to use such test specimens
that are similar to real machine components. The gear testing is incomparably more
expensive and time consuming than tests carried out on simple specimens. But the main
advantage is better reliability of the results obtained.
Concerning the most dangerous kinds of wear of gear wheels, two types can be specified:
scuffing and pitting. These forms have been described previously in this study.
3.1 Component method for evaluation of scuffing resistance of gears
The test method for the evaluation of scuffing resistance of gears has been originally
developed by FZG (Gear Research Centre) at the Technical University of Munich. This
method was adapted for investigation of PVD/CVD coated gears at ITeE-PIB.
All test gears are case carburised, with HRC 60 to 62 surface hardness and case depth of 0.6
to 0.9 mm. A test gears are cross-Maags ground, and their tips are especially shaped to
achieve high sliding velocities, hence the tendency to scuffing. The tested PVD/CVD
coating can be deposited on one or both gears Fig. 12.
Fig. 12. Coated test gears used for testing scuffing - type A
The only limitation is the deposition temperature that should be below 180C, which is
connected with thermal stability of gear material.
Special coated gears (e.g. A20 type) are run in the test lubricant, at constant speed for a fixed
time, in dip lubrication system. From load stage 4 the initial temperature is controlled. The
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oil is heated up to 90C. Loading of the gear teeth is raised in stages. During the running
time of each load stage the oil temperature is allowed to rise freely. After load stage 4 the
pinion gear teeth flanks are inspected for damage and any changes in tooth appearance are
noted. The maximum load stage is 12. If the summed total width of the damaged areas on
all the pinion gear teeth faces is estimated to equal or exceed one gear tooth width then this
load stage should be taken as the failure load stage (FLS). Additionally the oil temperature,
vibration level and motor load during the test can be measured.
The main advantage of the method is the possibility of scuffing testing of various materials,
surface coatings as well as various lubricants intended for heavy-loaded friction joints.
Furthermore the test can be realised by means of the worldwide popular back-to-back gear
test rig manufactured by many producers.
Hertzian
Load
stress at pitch
stage
point pmax
[MPa]
4
621
5
773
6
927
7
1080
8
1232
9
1386
10
1538
11
12
1691
1841
a-C:H:W
light scars
light scars
light scars
light scars
light scars
light scars
light scars
a-C:Cr
face polished
face polished
face polished
face polished
face polished
face polished
wide scuffing
areas
light scars
light scars
a-C:H
none
none
none
light scars
light scars
light scars
light scars
numerous scars
numerous scars
Table 1. The teeth failure at load stage for various DLC coatings (gears lubricated with eco-oil)
12
11
10
9
8
7
6
5
4
3
2
1
0
uncoated
WC/C (a-C:H:W)
DLC (a-C:Cr)
DLC (a-C:H)
Fig. 13. Failure load stages for uncoated steel gears and for teeth coated with DLC coatings
lubricated with eco-oil (A/8.3/90 method)
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The test method has been successfully used for extensive research to determine the effect of
ecological gear oils on scuffing resistance of coated gears and for the selection of coating
types for gear applications. An example of the research on gear oils is presented below.
The method has been applied for selecting a proper DLC coating for increasing the scuffing
resistance of gears. The results from gear tests are presented in Table 1 and Fig. 13.
For uncoated gears lubricated eco-oil the 10th failure load stage only was achieved. The
application of the coating (a-C:H:W or a-C:H) increased the scuffing resistance of gears.
They passed the maximum 12th stage without scuffing. Only a-C:Cr coating did not improve
the scuffing resistance of the tested gears.
The photographs of teeth surfaces after tests for tested DLC coatings (gears lubricated with
eco-oil) are presented in Fig. 14.
WC/C
(a-C:H:W)
DLC
(a-C:Cr)
DLC
(a-C:H)
Fig. 14. The photographs of teeth surfaces after tests for various DLC coatings (gears
lubricated with eco-oil)
The presented component method for evaluation of scuffing resistance of gears have been
applied for developing a new solution for manufacturing steel heavy-loaded machine
components covered with low friction coatings that enables increase service life of
components and allows lubricating with environmentally friendly oils. This will increase the
reliability of machines and reduce pollution of the environment by oil.
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Fig. 15. Coated test gears used for testing pitting type C-PT
The result of the tests is the LC50 fatigue life, related to 50% probability of failure. LC50 is
defined as the number of load cycles when the damage area of the most damaged tooth
flanks exceeds 4% (about 5 mm2). The total test time of each run is limited to 40 millions
load cycles at pinion (300 operating hours). In some cases other criteria can be used. At least
three valid runs are necessary to calculate the LC50 parameter.
The main advantage of the method is the possibility of comprehensive testing on various
low-friction and antiwear PVD/CVD coatings intended for heavy-loaded machine elements.
The method is realised by means of the worldwide popular back-to-back gear test rig.
The test method has been successfully used for extensive research to determine the effect of
low-friction and antiwear coatings on pitting wear. An example of the research on gear oils
is presented below.
The results indicate that for the coated/coated pair (pinion and wheel coated) and coated
pinion/steel wheel pair a significant decrease in the fatigue life compared to the uncoated
gears was obtained Fig. 16.
The best results were obtained in the case of the steel pinion/W-DLC coated wheel even
fourfold increase in the fatigue life was observed. This shows a very high potential of the
application of DLC coatings for gears.
Thanks to the component gear method for the evaluation of pitting wear of gears, it was
possible to overcome the main factor hampering application of thin coatings on heavy
loaded elements for many years i.e. their poor behaviour under cyclic stress conditions. This
new method will allow for selection of low-friction and antiwear PVD/CVD coatings
intended for manufacturing of steel heavy-loaded machine components. This will increase
the service life of components and allow for the application of environmentally friendly oils.
This will increase the reliability of machines and reduce environmental pollution.
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40
35
30
25
20
15
10
5
0
steel / steel
WC/C / steel
WC/C / WC/C
steel / WC/C
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performed - ISO 14635-1, 14635-2, 14635-3, CEC L-07-A-95, L-84-02, DIN 51354, IP 334,
ASTM D 5182, D 4998, PN-78/C-04169, FVA information sheets: 2/IV (1997), 54/7 (1993),
243 (2000). For the last few years, the T-12U Rig has been successfully used at ITeE-PIB for
the extensive research to determine an effect of modern gear oils (including ecological oils)
on different forms of gear tooth wear, as well as possibility of improving the gear life by the
deposition of low-friction coatings.
4. Conclusion
Presented methods give the possibility of comprehensive testing on various low-friction and
antiwear PVD/CVD coatings intended for machine elements. All the presented methods
and both tribotesters i.e. T-02U Universal Four-Ball Testing Machine, T-12U Universal Backto-back Gear Test Rig have been implemented at the Tribology Laboratory of ITeE-PIB and
successfully verified. They are employed to perform various kinds of projects e.g. grants,
R&D projects, ordered by the Polish government and international projects (COST Actions,
6th EU Framework Programme). They are also used to realise research orders from Polish
industry (especially small and medium size enterprises) and the scientific sector (research
institutes, technical universities).
The new methods exhibit very good resolution and precision comparable to standardised
test methods and are time and cost effective. Furthermore the cone-three ball method gives
the possibility of testing fatigue wear of any coating and substrate material. Basing on the
elaborated methods the optimal selection and development of PVD/CVD technologies
applied for extension of the life of the heavy-loaded friction joints as well as the elimination
of toxic lubricating additives have been obtained.
The further development of tribological devices is performed in the frame of Strategic
Programme Innovative Systems of Technical Support for Sustainable Development of
Economy, which is currently realised at the Institute for Sustainable Technologies-National
Research Institute (ITeE-PIB) in Radom, in Poland. The Programme is realised within the
framework of the Innovative Economy Operational Programme co-funded from European
structural funds. The greatest emphasis is put on the development of advanced machines for
testing spur gears and rolling bearings under extreme conditions.
5. References
Antonov, M., Michalczewski, R., Pasaribu, R. & Piekoszewski W. (2009). Assessment of the
potential of lubricated contact conditions laboratory testing and surface analysis for
improving the performance of machine elements. Comparision of model and real
components test methods. Estonian Journal of Engineering, Vol. 15. No. 4, pp. 349358, ISSN 1736-6038
Burakowski, T.; Szczerek, M. & Tuszynski, W. (2004). Scuffing and seizure - characterization
and investigation, In: Mechanical tribology. Materials, characterization, and
applications, Totten, G.E. & Liang, H., (Ed.), pp. 185-234, Marcel Dekker, Inc., ISBN
0-8247-4873-5, New York-Basel
Libera, M., Piekoszewski, W. & Waligra W. (2005). The influence of operational conditions
of rolling bearings elements on surface fatigue scatter. Tribologia. 2005, No. 3, pp.
205215, ISSN 0208-7774
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ISBN 978-953-307-371-2
Hard cover, 320 pages
Publisher InTech
How to reference
In order to correctly reference this scholarly work, feel free to copy and paste the following:
Remigiusz Michalczewski, Witold Piekoszewski, Waldemar Tuszynski, Marian Szczerek and Jan Wulczynski
(2011). The New Methods for Scuffing and Pitting Investigation of Coated Materials for Heavy Loaded,
Lubricated Elements, Tribology - Lubricants and Lubrication, Dr. Chang-Hung Kuo (Ed.), ISBN: 978-953-307371-2, InTech, Available from: http://www.intechopen.com/books/tribology-lubricants-and-lubrication/the-newmethods-for-scuffing-and-pitting-investigation-of-coated-materials-for-heavy-loaded-lubricat
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