201062601

School of Mechanical
Engineering

MECH5825M Professional Project

Scoping and Planning Document

Student Name: V. Sandeep Reddy

Programme of Study: M.Sc. Automotive engineering

Provisional Title of Project:

Tribology and Tribochemistry of diamond like carbon (DLC) coatings

Supervisor(s) Name(s): Dr. shahriar koseriah

Type of Project: Experimental

Signature of Student: Date: 13/1/2017

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1. SCOPE OF THE PROJECT

In recent years (Diamond like carbon) DLC coatings along with lubricant additives
Molybdenum dithiocarbomate (MoDTC) and Zinc dialkyldithiophosphate (ZDDP) are
showing huge potential in automotive field with reducing friction, wear performance of
materials and thus directly increase the fuel economy and minimizes the emission of
harmful gases/particles into the environment. The tribological performance of DLC
coatings with lubricants is not clearly understood as the research of how lubricant
additives react with non-ferrous coatings like DLC is still non-conclusive. Recent
publications report that MoDTC a friction modifier is causing high wear of DLC coatings
and ZDDP an anti-wear additive is shown to reduce the MoDTC caused wear but it
also increases the friction. So a better understanding of the lubricant performance with
DLC coatings and how it interacts with different additives is required. This project aims
to investigate the tribological performance of DLC coatings with MoDTC and ZDDP
and to understand the chemistry between the materials for better understanding so as
to optimize the lubricant suitable for (non-ferrous) DLC coatings.

1.1 Project Aim

To study the tribological performance of DLC coatings with lubricant additives (MoDTC
and ZDDP) and also analyse the chemical interaction between the materials.

1.2 Project Objectives

i. To investigate the performance of DLC coating on a steel surface with different

lubricant additives using a pin on plate tribometer test.
ii. To analyse the friction and wear on plate using optical microscope and white
light interferometer.
iii. To validate the obtained results and perform retests if necessary.
iv. To examine the effect of MoDTC and ZDDP on the friction and wear
performance over the DLC coated steel plate.

1.3 Project Deliverables

 Project report with study on tribological performance of DLC coatings with

lubricant additives based on the pin on plate tribometer test results.
 Analysis on the chemical interactions of DLC coatings with lubricant additives.
 Presentation on the project study and the obtained results along with validation.

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2. PRELIMINARY LITERATURE REVIEW

2.1. Introduction to Tribology

The term tribology is relatively new and was coined by David tabor and Peter jost but
the field of tribology has been around for thousands of years. It is derived from the
greek word “tribos” which means rubbing. [1] Tribology can be defined as “the study of
science and engineering of interacting surfaces in relative motion”. It covers the subject
of friction, wear and lubrication. It is used to study the friction and wear generated
between interacting surfaces in a mechanical system which are rubbing or sliding
relative to each other.

2.1.1 Friction

when two surfaces are in relative motion the resistance force acting between the
surfaces is called friction. Friction can be useful and harmful based on the application.

2.1.2 Wear

Wear is the loss of material due to plastic deformation on the surface of two bodies
which are in relative motion and under load. Wear causes irregularities and
deformations on the surface which reduces the performance and life of the machines.

2.1.3 Lubrication

The process of interposing a substance between two surfaces in contact which are
relative motion to reduce the friction and wear is called as lubrication. [2] The
substance interposed is called as a lubricant. Lubricants can be solid, liquid or gas but
mostly they are liquids such as mineral and vegetable oils. Additives are added to the
base oil to add or alter the properties of the lubricant.

2.1.4 Lubrication regimes

Lubrication can be classified into four regimes. Based on different factors like, load,
conformity, surface material, operating conditions. They are Hydrodynamic lubrication,
Boundary lubrication, mixed lubrication, Elastohydrodynamic lubrication. [2]

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2.2 Pin on plate Tribometer

To simulate the friction, wear and lubrication between two surfaces in contact and
relative motion a Tribometer. [3] Using the tribometer the coefficient of friction, frictional
force, wear volume between can be calculated. [3]. Pin on plate tribometer is illustrated
in the below figure-1.

Fig-1 Schematic illustration of Pin on plate tribometer test. [4]

this test has been proved useful for testing the friction and wear of DLC coatings on
valve-train system in IC engines. In this project DLC coated HSS (high speed steel)
plate of dimensions 15x6x3cm, cast-iron pin and with lubricants will be used for testing.

2.3 (DLC) Diamond like carbon coatings

Diamond like carbon coating are thin film carbon coatings which possess identical
properties of diamond. DLC are made up of sp2 and sp3 amorphous structure bonding.
[5] They have a unique combination of qualities that no other single surface treatment
offers such as self-lubrication, resistance to adhesive, abrasive, corrosive wear. [5]
They provide electric resistance and high wear resistance. DLC coated surfaces have
low coefficient of friction and high wear resistance.

2.4 Valve train components with DLC coatings

The operation of valves in an IC engine are controlled using the valve train. [6] It is a
very important component where the potential for reducing the friction is high. 20-30%
of the friction in an automotive engine can be accounted to the cam follower system.
[7] multiple methods are used to reduce the surface roughness between cam and cam
follower. [7] Highest loads are seen at the tappet and at this material there is a lot of
energy loss due to friction. [8] DLC coatings have proven to provide very efficient in

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reducing the frictional losses in valve trains and also wear. Nissan came up with this
technology in 2007 and demonstrated that by coating DLC on valve lifters friction has
been reduced by 40%. [9] They estimate that 25% overall friction in an engine can be
reduced using this process. [9] Dry DLC coatings perform very will but DLC coatings
with lubricants provide varied results. Different additives provide different levels of
friction and wear in this system. So choosing the optimised lubricant for DLC coatings
is very crucial to improve the performance of engine and fuel economy.

2.5 Effect of MoDTC and ZDDP on DLC coatings

MoDTC (Molybdenum Dithio carbamates) is a well-known friction modifier that

provides low friction on the ferrous surfaces. [10] ZDDP (Zinc Dialkyl-
dithiophosphates) is a widely used anti-wear additive that forms a film on the ferrous
surface to protect from wear. DLC is chemically inert and doesn’t react with lubricant
additives. [10] but recently some studies show that DLC coating with only MoDTC is
causing high wear on the surface along with reduction in coefficient of friction.

The use of only ZDDP with DLC has shown improvements in wear performance but
also increase in friction. [10] ZDDP also acts as anti-oxidant and corrosion inhibitor. In
a report by sugimoto, it is shown that the DLC coating with both MoDTC with ZDDP
provides less friction and less wear. [11] the wear caused by MoDTC was reduced by
ZDDP. Still the friction levels are relatively high due to ZDDP, so an optimized lubricant
needs to be created for improving the performance in valve trains with DLC coatings.
Further study needs to be done on the effect of MoDTC and ZDDP on DLC coatings
as there are some reports which provide contradictory results to the above studies. So
there is an opportunity to research the different effects of lubricant additives on DLC
coatings. The effect of lubricant additives on such non-ferrous surfaces is still not
completely understood.

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3. PROJECT WORK PLAN

3.1 Work Breakdown

This project work can be separated into three different segments

 Literature review
 Experiment in lab and analysis of results
 Final report

3.1.1 Tasks, Milestones and Timeline

The different tasks and milestones that needs to be performed along with a timeline
are mentioned in the below table-1. (Milestones are highlighted in red)

TASKS NUMBER

Literature review T1

Finalising aims and objectives of project T2

Scoping and planning document T3

Lab induction T4

Lab training T5

Acquiring test samples T6

Laboratory tests on samples T7

Analysis of test results T8

Repeat tests T9

Further analysis of test results T10

Validation of results T11

Discuss with supervisor and interpret T12

the results

Finishing the final report T13

Submit to supervisor for review T14

Oral presentation T15

Final report submission T16

Table-1 tasks and milestones for the project.

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3.1.2 Gantt chart

Note- C -indicates Christmas, E- indicates easter, S- indicated summer

3.2 project risk assessment

 Unavailability of lab equipment- to avoid this proper scheduling of lab timings

is necessary
 Misplacement of test samples- proper labling of samples is adviced
 Error in the results- recheck and validation is important to avoid this problems
,if necessary run retests
 Chemical mishandling- proper care should taken while handling dangerous
chemicals
 Health issues- in such events proper communication with supervisior and
avoiding delay is suggested.

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REFERENCES
1. En.wikipedia.org. (2017). Tribology. [online] Available at:
https://en.wikipedia.org/wiki/Tribology [Accessed 13 Jan. 2017].
2. En.wikipedia.org. (2017). Lubrication. [online] Available at:
https://en.wikipedia.org/wiki/Lubrication [Accessed 13 Jan. 2017].
3. En.wikipedia.org. (2017). Tribometer. [online] Available at:
https://en.wikipedia.org/wiki/Tribometer [Accessed 13 Jan. 2017].
4. ma, J. (2017). Schematic illustration of pin-on-plate tribometer.. [image]
Available at: https://www.researchgate.net/publication/223013713 [Accessed
13 Jan. 2017].
5. boghe, m. (2010). DLC Coatings for Increased Wear Resistance. [online]
Gearsolutions.com. Available at:
http://www.gearsolutions.com/article/detail/5996/dlc-coatings-for-increased-
wear-resistance [Accessed 13 Jan. 2017].
6. En.wikipedia.org. (2017). Valvetrain. [online] Available at:
https://en.wikipedia.org/wiki/Valvetrain [Accessed 13 Jan. 2017].
7. kano, m. (2006). Super low friction of DLC applied to engine cam follower
lubricated with ester-containing oil. [online] sciencedirect. Available at:
http://www.sfplayers.com/blog/dlcPapers/Kano_2006_Tribology-
International.pdf [Accessed 13 Jan. 2017].
8. http://www.cs2.ch, C. (2017). Ionbond - Valve Train. [online] Ionbond.com.
Available at: http://www.ionbond.com/en/coating-
services/components/racing/valve-train/ [Accessed 13 Jan. 2017].
9. Hareyan, A. (2007). Nissan's Hydrogen-Free DLC Coating Wins Meti Award.
[online] HULIQ. Available at: http://www.huliq.com/32228/nissans-hydrogen-
free-dlc-coating-wins-meti-award [Accessed 13 Jan. 2017].
10. Kosarieh, S., Morina, A., Lainé, E., Flemming, J. and Neville, A. 2013. The
effect of MoDTC-type friction modifier on the wear performance of a
hydrogenated DLC coating. Wear. 302(1-2),pp.890-898.
11. SUGIMOTO, I. 2012. Mechanism on Specific Wear of DLC Film in Engine Oil
with Mo-DTC. TRANSACTIONS OF THE JAPAN SOCIETY OF
MECHANICAL ENGINEERS Series A. 78(786),pp.213-222.

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APPENDIX A. ETHICAL REVIEW

The project doesn’t require an ethical review because of the following reasons
The project doesn’t involve any human participants
Furthermore, the project doesn’t impact the environment as it doesn’t involve the
usage of any toxic chemicals