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Wear
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a r t i c l e i n f o a b s t r a c t
Article history: Coatings are more and more used to reduce friction or resist wear of contacting surfaces. However, the
Received 1 September 2010 selection of the optimal coating from many possibilities is still difcult for a given tribological application.
Received in revised form In the present work, a systematic approach is suggested to help the selection of tribological coatings.
19 November 2010
Firstly, a pre-selection tool based on database is developed to pick out several coatings as candidates
Accepted 21 November 2010
for performing further tests. In the pre-selection tool, many industrial tribological coatings are included,
and they can be ranked according to the extent that they meet the requirements of a given tribological
application. Next, some simple evaluation techniques (nanoindentation test, scratch test, ball cratering
Keywords:
Tribological coating
test, etc.) are used to assess the properties of the candidate coatings to screen out some poor ones. Then,
Pre-selection tool the remaining coatings are tested under the relevant conditions to investigate their tribological behaviors.
Coating selection According to the test results, a dissipated energy density approach can be easily used to evaluate and
Dissipated energy compare their tribological performance, because the relationship between coating lifetime and dissipated
Polar diagram energy density can be tted as one master curve whatever the values of test parameters. Finally, in view
of non-tribological and non-functional requirements, the coatings are synthetically compared using a
exible polar diagram, and a weight point method can assist the comparison.
2011 Elsevier B.V. All rights reserved.
0043-1648/$ see front matter 2011 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2010.11.049
D.B. Luo et al. / Wear 271 (2011) 21322143 2133
coating selection process should include two stages [3,5]. The rst ing and comparing the tribological performance of coatings will be
one is pre-selection, i.e., picking out several candidates from avail- suggested based on some experimental studies.
able coatings according to the requirements of the application and
the characteristics of coatings and deposition processes. The second
stage is to evaluate the candidate coatings by experiments, and then 2. Pre-selection methodology
to select the best one. Franklin [5] summarized the two stages and
provided two industrial tribological case studies involving coating During a coating pre-selection process, known conditions,
selection. For most industrial applications, candidate coatings are requirements of the application, and properties of the coatings
often selected according to experts experience [6], which is inef- and deposition methods should be comprehensively considered,
cient and the selected coating can be not the most suitable one due and the candidate coatings will be selected based on some
to the limitation of experts experience. appropriate criteria. Fig. 2 shows the diagram of pre-selection
Pre-selection process of coatings, selecting several coatings process. For a given application, the application conditions (con-
from hundreds of thousands of possibilities, is a complicated work, tact conguration, load, kinematic, etc.), counterpart (material,
so the best way is to develop some tools, like expert systems, topography, geometry, mechanical and chemical properties, etc.),
databases or information systems. The research group of Matthews substrate (material, topography, shape, size, mechanical, ther-
and co-workers [7,8] developed several knowledge-based expert mal and chemical properties, etc.) and running environments
systems for tribological coating selection in their early work. A PRE- (lubrication, temperature, RH, atmosphere, etc.) should be known.
CEPT system [9,10] was developed to assist the selection of surface According to the known conditions, some analysis about the contact
engineering during the initial stages of engineering design accord- conguration and the possible failure mechanisms of the rubbing
ing to different wear design rules. Dobrzanski and Madejski [11] surface must be performed to investigate the dominant wear mech-
designed an expert system prototype to select coatings for met- anisms, which induces some requirements for mechanical, physical
als, where the candidate coating was selected using a weighted and chemical properties of the coatings. The known conditions also
total point in the light of requirements of the application and the bring some limits for coatings. On the other hand, there are also
extent that the coatings meet the requirements. Landru [12] devel- some denite requirements for the coated surface from end users,
oped a simple surface treatment selector in his thesis work, where which include tribological functional requirements (changing or
a percentage was used to express the condence level of the selec- reducing friction, prolonging service lifetime, etc.), non-tribological
tion. Schiffmann et al. [13] developed a web-based information functional requirements (corrosion resistance, thermal, electrical,
system for coating selection, where a qualitative, fuzzy classi- magnetic, biocompatible, etc.) and non-functional requirements
cation scale was introduced to describe material properties and (cost, productive efciency, ecological, etc.)[5]. The candidate coat-
coating characteristics. The best match coating was selected by ings are selected matching the requirements and limits from the
the root-mean-square deviation between the target value and the application with characteristics of the coatings in the database.
value of coating properties. Up to now, only PVD and CVD coatings
are included in this system. With the consideration of qualitative
properties, Athanasopoulos et al. [14] developed an expert system 2.1. Requirements from applications
model for coating selection based on fuzzy logic. Some of these
systems are behind the times, and the others are just prototype For a given tribological application, there are many require-
models. ments for the coatings, including tribological performance,
In this work, we present a coating pre-selection tool based on non-tribological performance and non-functional requirements
database developed comprehensively using the selection strategies [3,5], which are listed in Table 1. They come from the direct
in literature and including most industrial coatings. On the other demands of end users, or from the analysis of contact conguration
hand, some more effective and easy to use approaches for evaluat- and failure mechanisms.
2134 D.B. Luo et al. / Wear 271 (2011) 21322143
tance, and their thermal expansion coefcient should be close to the selected deposition processes must ensure the coating with-
that of the substrate to avoid the development of thermal stresses. out build-ups and detachments from the substrate at the sharp
edges. For selective deposition with a large blank area, the deposi-
2.2.1.2. Atmosphere. Atmosphere means the running medium tion methods where the whole component is immerged in a bath or
environment of the coated components, usually including ambi- gaseous circumstance (coating material particles) are unreasonable
ent air, vacuum, high vacuum, nitrogen, oxygen, hydrogen and because a lot of stopoff media needs to be used.
inert gases. Coatings tending to be oxidized, like MoS2 , present
better tribological performance in the atmosphere without oxy-
2.2.3. Limits from the counterpart
gen [15]. a-C:H coatings have a longer lubricating lifetime in an
The hardness, roughness and chemical properties of the coun-
inert environment due to low friction coefcient and low wear
terpart can inuence the tribological performance of a coating
rate, while a-C coatings show lower friction coefcient in ambient
system. When the counterface is hard and rough, hard coatings will
air [4]. Coated components can also work in liquid environment,
be expected, in order to resist abrasive wear. For adhesive wear and
like water, seawater, lubricant and various chemical agents, where
diffusion wear applications, the selected coating material should be
coatings with poor corrosion resistance and cavitation resistance
chemically stable, in order to reduce adhesion and diffusion with
should be excluded.
the counterface.
2.2.1.3. Relative humidity. Relative humidity can inuence friction,
wear and corrosion performance of coatings. Therefore, different 2.3. Pre-selection criteria
coatings will be expected for different relative humidity conditions.
For example, MoS2 and DLC (a-C:H) coatings should be used under A coating is an integration result of coating material, coating
dry or low RH conditions; graphite, PVD TiN and DLC (a-C) coatings structure and deposition method. Specic deposition parameters,
are suitable for high RH conditions. matching between the coating material and the deposition method,
are not the focus in this work. Therefore, the coatings mentioned in
2.2.1.4. Loading. Loading, including its type (static, alternating, the subsequent paragraphs are the common coatings in industries
impact) and value, leads to different requirements for coating prop- expressed by deposition method plus coating material.
erties. For example, under the alternating load, the fatigue strength The pre-selection of coatings is the process of matching the char-
of the coatings may be important; under impact load, the toughness acteristics of coatings with the requirements and limits from the
of the coatings can be crucial; under high load (contact pressure), tribological application. The following criteria should be considered
thick coatings with high hardness will be expected. during the matching process.
10, x x0 ments is 10, and it cannot be changed. The weight factor of the
k = f (x) = (3) Negotiable requirements can be set by end users.
10 x , x < x0 Reliability is used based on some presumption in view of the
x0
incompletion of coating data. The total reliability (R) is the product
10, |x x0 | t of the reliability for each requirement (r) (Eq. (5)).
k = f (x) = t (4)
n
10 , |x x0 | > t R= ri (5)
|x x0 |
i=1
where x0 is the expected value of the relevant property, x is the
value of the relevant property for a coating, t is a tolerance away The reliability of each requirement, ri , can be set according to
from the certain value of the relevant property. the following rules:
The weight factor reects the importance of the relevant
requirement. It can be chosen from 1 to 10 (1least important, When the relevant coating property of a requirement is denitely
10most important). The weight factor of Must be met require- provided, the reliability of the coating equals to 100%.
D.B. Luo et al. / Wear 271 (2011) 21322143 2139
4.1. Screening candidate coatings In Fig. 10, the coating lifetime strongly depends on the values of
test parameters (normal load and displacement amplitude), so it is
When several candidate coatings are selected from the pre- not easy to compare coatings by changing lifetime curves, espe-
selection tool, it is time consuming to test all of them by tribological cially when a superposition of their lifetime curves occurs (like
experiments. Some properties of the coatings (like hardness, elastic K03 and K06). In fact, some parameters (like friction coefcient,
modulus, bonding strength, thickness, etc.) are very important for normal load and sliding distance) can be unied as one parame-
the tribological performance; so rapidly evaluating these coating ter: dissipated energy. Mohrbacher et al. [27] found that there is
properties through some simple techniques is an efcient method a linear relationship between wear volume and cumulated dissi-
of screening the candidate coatings. According to Archard model, pated energy. However, the most important for coating lifetime is
there is a linear relationship between wear volume and the inverse not wear volume but wear depth, which is linked to the cumulated
of hardness of a bulk material [23], and coatings with high hardness local dissipated energy (or dissipated energy density) [28]. It is dif-
generally present good wear resistance [2426]. Therefore, coating cult to obtain the cumulated local dissipated energy due to the
2140 D.B. Luo et al. / Wear 271 (2011) 21322143
Table 3
Basic characteristics of the bonded coatings [21].
Table 4
Fretting test conditions.
Test type Normal load P (N) Displacement amplitude * (m) Frequency (Hz) Test duration (cycles) Temperature ( C) Relative humidity (%)
Table 5
Unidirectional sliding test conditions.
Test type Normal load P (N) Rotating speed Distance R (mm) Sliding speed (m/s) Test duration Temperature Relative humidity
(r/min) (cycles) ( C) (%)
Fig. 9. (a) Wear rate of the coatings under 1 N and 60 rpm; (b) micrograph after K15 worn through.
Table 6
Properties of the coatings [21].
Table 7
Rank of the 5 coatings by their properties [21].
K39 1 4 1 1 1 1
K15 5 3 4 2 2 2 (with severe detachment)
K03 3 5 2 3 3 3
K06 4 1 5 5 4 4
U22 2 2 3 4 4 5
evolution of contact area and contact pressure with rubbing pro- tion (Eq. (8)), which takes place at the dashed circle formed by the
cess. Therefore, an initial maximal dissipated energy density (Ed0 center points of the contact areas (Fig. 11).
max ini ) approach [29] is more practical for industrial applications.
Under a given contact conguration, change of test parameters in a E = 4ini 0ini pmax (6)
d0 max ini
certain range cannot usually result in change of wear mechanism,
and the evolution trends of contact conditions with rubbing pro- x2
cess are similar for different values of test parameters. So, the initial p(x) = pmax 1 (a x +a) (7)
a2
dissipated energy density can be used to represent the cumulated
dissipated energy density. On the other hand, if the change of test
parameters results in different wear mechanisms, this approach
+a +a
x2
can be dubious. E = ini p(x)dx = ini pmax 1 dx
d0 max ini a2
For ball on at and cylinder on at fretting congurations, Fou- a a
vry [30] provided the accurate equations of the maximal dissipated
energy density in a cycle. Fridrici et al. [29] gave a simple approxi- 1
= ini pmax a (8)
mate equation (Eq. (6)), whose results in the gross slip regime are 2
very close to those of Fouvrys equations. For ball on disk unidi- where pmax is the maximal contact pressure, ini and 0ini are
rectional sliding contact, the maximal dissipated energy density respectively the friction coefcient and actual displacement ampli-
should take place at the point related to the maximal pressure, tude in initial cycles, and a is the contact radius.
which should be the center point of the contact area according to According to Eqs.(6) and (8), the relationship between the life-
Hertzian contact pressure distribution (Eq. (7)). The relative shear time of the pressure sprayed MoS2 coating and Ed0 max ini is shown
stress distribution is obtained by multiplying the contact pressure in Fig. 12, where one master curve can be obtained for each contact
by friction coefcient (Fig. 11). In one cycle, the ball passes a point conguration whatever the values of test parameters.
of the disk once, so the maximal dissipated energy density is equal In view of this feature, the initial maximal dissipated density
to the integration of the shear stress distribution in the central sec- approach is helpful for comparing the tribological performance of
Fig. 10. Effect of test parameters on coating lifetime: (a) K03; (b) K39; (c) K06; (d) U22 and K15.
2142 D.B. Luo et al. / Wear 271 (2011) 21322143
Fig. 11. Distribution of contact pressure and dissipated energy density for ball on disk sliding contact.
Table 8
Parameters used in the polar diagram.
Friction reduction
ref Mean value of friction coefcient
P Effect of normal load on friction
coefcient
Effect of displacement amplitude
on friction coefcient
Fig. 13. Ed0 max ini Nc master curves for the bonded coatings.
Table 9
Evaluate the coatings by weight point.
Parameters
ref P cref
N NcP Nc D Lc Kb h Kc T K39 K03 K06
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