Tribological behaviour of an electrochemical jet machined textured Al-Si automotive cylinder liner material
This paper investigates the use of Electrochemical Jet Machining to surface texture a hyper-eutectic Al-Si cylinder liner material. Samples were lapped to a 6μm finish followed by immersion in 1mol NaOH to expose the primary silicon colonies above the aluminium surface. Texturing was carried out usi...
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| Published in: | Wear Vol. 376-377; no. PB; pp. 1611 - 1621 |
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Elsevier B.V
15-04-2017
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| Abstract | This paper investigates the use of Electrochemical Jet Machining to surface texture a hyper-eutectic Al-Si cylinder liner material. Samples were lapped to a 6μm finish followed by immersion in 1mol NaOH to expose the primary silicon colonies above the aluminium surface. Texturing was carried out using a NC system comprising of a fine gauge nozzle (cathode) jetting a solution of 2.3mol NaCl on the surface (anode) whilst applying a current density of 220A/cm2. An array of hemispherical dimples at 1.5mm spacing was created, with an average diameter of 420μm and depth of 40μm, corresponding to an ε ratio of 0.095. Lubricated reciprocating sliding was carried out at stroke length of 25mm in a bath of PAO (4cSt) against a 52100 cylinder of 6mm diameter and 16mm length. Sliding frequencies were incremented at 1Hz intervals between 1–15Hz at 50N load increments from 50-200N. Stribeck curves indicated a reduction of the friction coefficient due to texturing of up to 0.05 in the mixed lubrication regime, representing a decrease of 38.5%. Optical profilometry and SEM indicated that abrasion and formation of a surface tribo-layer was mitigated in regions of the Al-Si surface where textured features were present parallel to the sliding direction.
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•Electrochemical Jet Machining was used to texture a hyper-eutectic Al-Si alloy.•Textured features exhibited no evidence of edge burs or lips.•Friction coefficients were reduced by up to 38.5% as a result of the texturing.•Texturing enhanced debris removal, preventing formation of a surface tribo-layer. |
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| AbstractList | This paper investigates the use of Electrochemical Jet Machining to surface texture a hyper-eutectic Al-Si cylinder liner material. Samples were lapped to a 6μm finish followed by immersion in 1mol NaOH to expose the primary silicon colonies above the aluminium surface. Texturing was carried out using a NC system comprising of a fine gauge nozzle (cathode) jetting a solution of 2.3mol NaCl on the surface (anode) whilst applying a current density of 220A/cm2. An array of hemispherical dimples at 1.5mm spacing was created, with an average diameter of 420μm and depth of 40μm, corresponding to an ε ratio of 0.095. Lubricated reciprocating sliding was carried out at stroke length of 25mm in a bath of PAO (4cSt) against a 52100 cylinder of 6mm diameter and 16mm length. Sliding frequencies were incremented at 1Hz intervals between 1–15Hz at 50N load increments from 50-200N. Stribeck curves indicated a reduction of the friction coefficient due to texturing of up to 0.05 in the mixed lubrication regime, representing a decrease of 38.5%. Optical profilometry and SEM indicated that abrasion and formation of a surface tribo-layer was mitigated in regions of the Al-Si surface where textured features were present parallel to the sliding direction.
[Display omitted]
•Electrochemical Jet Machining was used to texture a hyper-eutectic Al-Si alloy.•Textured features exhibited no evidence of edge burs or lips.•Friction coefficients were reduced by up to 38.5% as a result of the texturing.•Texturing enhanced debris removal, preventing formation of a surface tribo-layer. This paper investigates the use of Electrochemical Jet Machining to surface texture a hyper-eutectic Al-Si cylinder liner material. Samples were lapped to a 6 μm finish followed by immersion in 1 mol NaOH to expose the primary silicon colonies above the aluminium surface. Texturing was carried out using a NC system comprising of a fine gauge nozzle (cathode) jetting a solution of 2.3 mol NaCl on the surface (anode) whilst applying a current density of 220 A/cm2. An array of hemispherical dimples at 1.5 mm spacing was created, with an average diameter of 420 μm and depth of 40 μm, corresponding to an ε ratio of 0.095. Lubricated reciprocating sliding was carried out at stroke length of 25 mm in a bath of PAO (4 cSt) against a 52100 cylinder of 6mm diameter and 16mm length. Sliding frequencies were incremented at 1 Hz intervals between 1–15 Hz at 50 N load increments from 50-200 N. Stribeck curves indicated a reduction of the friction coefficient due to texturing of up to 0.05 in the mixed lubrication regime, representing a decrease of 38.5%. Optical profilometry and SEM indicated that abrasion and formation of a surface tribo-layer was mitigated in regions of the Al-Si surface where textured features were present parallel to the sliding direction. |
| Author | Clare, A.T. Mitchell-Smith, J. Kamps, T.J. Lam, J.W. Walker, J.C. |
| Author_xml | – sequence: 1 givenname: J.C. surname: Walker fullname: Walker, J.C. email: j.walker@soton.ac.uk, jcw101@hotmail.com organization: National Centre for Advanced Tribology (nCATS), University of Southampton, Southampton, UK – sequence: 2 givenname: T.J. surname: Kamps fullname: Kamps, T.J. organization: National Centre for Advanced Tribology (nCATS), University of Southampton, Southampton, UK – sequence: 3 givenname: J.W. surname: Lam fullname: Lam, J.W. organization: National Centre for Advanced Tribology (nCATS), University of Southampton, Southampton, UK – sequence: 4 givenname: J. surname: Mitchell-Smith fullname: Mitchell-Smith, J. organization: Advanced Component Engineering Laboratory (ACEL), University of Nottingham, UK – sequence: 5 givenname: A.T. surname: Clare fullname: Clare, A.T. organization: Advanced Component Engineering Laboratory (ACEL), University of Nottingham, UK |
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| Keywords | Surface texturing Electrochemical jet machining Friction Al-Si Wear Automotive |
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| SubjectTerms | Abrasion Al-Si Aluminum Automotive Automotive parts Coefficient of friction Cylinder liners Dimpling Electrochemical jet machining Friction Friction reduction Lubrication Machining Nozzles Silicon Sliding Sodium chloride Sodium hydroxide Submerging Surface layers Surface texturing Texturing Tribology Wear Weight reduction |
| Title | Tribological behaviour of an electrochemical jet machined textured Al-Si automotive cylinder liner material |
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