umt tribolabtm for automotive applications · and comparison (ranking) cam and follower • umt...

UMT TriboLabTM for Automotive Applications Suresh Kuiry, Ph.D.

January 21, 2016 2

Introduction

Bruker Confidential

Innovation in Automotive

Energy Efficiency

Safety

Environmental Concerns

INNOVATION in

Automotive

Test

ing

Automakers

Research Organizations

Part Suppliers

Product Differentiation

Extent of Value- addition

Comparative Data

January 21, 2016 3

Introduction

Bruker Confidential

Bruker’s

UMT TriboLab

January 21, 2016 4

UMT TriboLab Applications

Numerous Automotive components can be tested for their Quality

and Performance using UMT TriboLab system - a few examples:

• Paints and coating (Scratch, Hardness)

• Lubricants (Comparative Stribeck Curves)

• Clutch and brake materials (Friction, Wear)

• Bearing (Wear)

• Tires (Friction, Wear)

• Piston ring and cylinder liner (Friction, Wear)

• Elastomers (Shore Hardness, Mechanical Properties)

• Engine valve (Hot Hardness)

• Wind shield (Scratch/Mar Resistance)

• Mirror (Stiction, Scratch Resistance)

Bruker Confidential

Bruker Confidential January 21, 2016 5

Test Methods

Tribological

• Friction (Static, Dynamic, Stiction)

• Wear and Wear Durability

Mechanical

• Hardness (Classical and Instrumented methods)

• Young’s modulus (instrumented indentation)

• Flexural stress-strain and elasticity in bending

• Scratch Test (Adhesion and Mar Resistance)

January 21, 2016 6

Bruker’s UMT TriboLab

o The system is built on the Universal

Mechanical Test (UMT) platform with precision

control of load, speed, and position.

o Most sophisticated and versatile tribology test

system ever designed

• Modular and Innovative

• Broadest Capabilities

• Unmatched Ease of use

o Real Time Control and Data Analysis software

to ensure high accuracy and repeatability of

test data.

Bruker Confidential

• Modular and Innovative Design ensures the maximum flexibility

- Single motor to cover full torque and speed ranges

- Easy to configure for any tribological or mechanical tests

- Interchangeable lower drives

• Broadest Capabilities

- Force (1mN to 2kN)

- Torque (up to 5N·m)

- Speed (0.1 to 5000 rpm)

- Temperature (-30 to 1000oC)

- Humidity (5 to 85%RH)

January 21, 2016 7


Bruker Confidential

Self-centering

Coupler Blind-mate Electrical

Connecters

TriboID Chip

Tool-less

Clamping

Pre

cis

ion

Base-r

ing

January 21, 2016 8


• Unmatched Ease of Use due to Intelligent hardware and

software interfaces making it user-friendly, versatile, and

productive.

- TriboIDTM automatically detects and configures

components that are plugged into the TriboLab system

- TriboscriptTM offers an enhanced and secured scripting

interface with Operator and Expert Modes of scripting

environment for running test at ease vis-a-vis preserving

the universality towards advanced test script

development using test-block methodology.

Bruker Confidential

January 21, 2016 9

UMT TriboLab Drives

Bruker Confidential

January 21, 2016 10

Liquid and Environmental Chambers

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BOR Heating

Chamber

Rotary Humidity

Chamber

Rotary Liquid Chamber Rotary Heating Chamber

January 21, 2016 11

Friction Test

Friction: The resistance force that one surface or object encounters

when moving over another.

o Sledge Friction Test (flat-on-flat) (ASTM D1894)

o Ball-on flat, Pin-on-flat, cylinder-on-flat

Z

X

F

FCOF )(

Sliding

Fz

Fx

Bruker Confidential

tan

mg

January 21, 2016 12

Sledge Friction

Sliding

Fz

Fx

Dynamic

Static

Sliding Distance

Static and dynamic friction of solid surfaces

Bruker Confidential

January 21, 2016 13

Lubricant Test: Stribeck Curve

Stribeck curve

• to evaluate lubricants for

their potential applications

and comparison (ranking)

• UMT TriboLab can cover

all three regions in wide

ranges of force, speed,

and temperatures

Bruker Confidential

Boundary Mixed Hydrodynamic

Piston Ring

Cam and Follower

Engine Bearing

Stribeck Curve of Lube A with ECR

January 21, 2016 14

Comparative Stribeck Curves

Stribeck curves of Lubes A and B showing differences in

Boundary and Mixed regimes

Bruker Confidential

Boundary Mixed Hydrodynamic

January 21, 2016 15

Wear Durability Test

• Testing tool tip –ball, Rockwell

diamond stylus

• Special probes such as ECR and AE

measurements

Bruker Confidential

January 21, 2016 16

Wear Durability Test of Paints

Wear Durability test results on painted panels using ECR option.

Bruker Confidential

January 21, 2016 17

Wear Test

Thrust Washer (ASTM D3702-Ring-on-disk)

Test is designed for the evaluation of wear

of bulk materials but this procedure can

also be used for measurement of wear

resistance of a coating. Fz and Torque (Tz)

are measured to obtain the evolution of

COF as function of Time.

Specific wear rate as the amount of

materials removed (mm3) with unit force (N)

and unit relative distance (m) travelled by

the wearing contact. The specific wear rate

is expressed in 𝑚𝑚3

𝑁.𝑚 unit.

Fz

Bruker Confidential

January 21, 2016 18

Wear Test of Coating

Test: 20 N, 300 rpm, 1 hr

Sp. Wear Rate = 6.85 x 10-5 𝑚𝑚3

𝑁.𝑚

Bruker Confidential

January 21, 2016 19

Constant Velocity Spiral Wear Test

Bruker Confidential

X

January 21, 2016 20

Piston Ring Cylinder Liner Test (ASTM G181 )

Step loading 100 -1600 N and back; Frequency-10Hz; Stroke-10mm

Bruker Confidential

January 21, 2016 21

Bearing Test with Conformal Contact

Conformal bearing test (BOR type drive): 2kN, 500 rpm; hot oil recirculation;

Torque measured with an inline torque sensor

Bruker Confidential

January 21, 2016 22

Hardness Test

Hardness indicates the resistance of a material against

plastic deformation.

• Hardness Tests: Brinell, Vickers, Knoop,

Rockwell, and Shore

• Instrumented Indentation Test: hardness and

Young’s modulus from load-displacement data

Bruker Confidential

January 21, 2016 23

Brinell, Vickers, Knoop Hardness

Brinell hardness (HB):

HB =2𝐹𝑧

𝜋𝐷 𝐷− 𝐷2−𝑑2

FZ is in kgf, D and d are in mm.

d

D

Fz

Vickers hardness (HV):

HV =2𝐹𝑧sin

𝛼

2

𝑑2

FZ is in kgf, = 136; d = (d1+d2)/2 in mm.

Knoop hardness (HK):

HK =14.229𝐹𝑧

𝑑2

FZ is in kgf, d is the long diagonal in mm.

d1

d2

d

Bruker Confidential

January 21, 2016 24

Rockwell and Shore Hardness

Rockwell hardness test applies an initial

load (FMinor), increased to a final value

(FMajor), then load is reduced to the initial

value. The difference in tip displacement

between two such minor loads relates

inversely to the hardness of specimen.

Shore hardness follows similar principle as Rockwell, but it differs in

load levels, tip materials, and geometry. It is primarily used for soft

materials such as elastomers.

z

FMinor FMajor

FMinor

Hardness (H): H = k – z.

Example: Hardness measurement in Rockwell C scale: FMinor= 10 kgf;

FMajor= 150 kgf; H = HRC; k = 100; z = permanent tip displacement of

diamond indenter in unit of 2 m.

Bruker Confidential

January 21, 2016 25

Hot Hardness

Hot hardness refers to the

hardness of materials at

elevated temperatures.

Hardness reflects the

strength of materials that

decreases with rise in

temperature. Mechanical

strength of Materials at High

temperature is an important

design parameter.

Usually high temperature mechanical properties of any materials are

evaluated by mechanical and creep rupture tests at elevated

temperatures. These tests are inherently time-consuming and difficult.

Hot hardness test using UMT TriboLab is a faster alternative. UMT

TrboLab has capability of high temperature test up to 1000 C. Engine

valve materials can be evaluated by measuring its hot hardness.

AISI 347 Stainless Steel

Bruker Confidential

January 21, 2016 26

Instrumented Indentation (Oliver-Pharr)

Load vs. Displacement Plots

E = 178.3±3.6 GPa

H = 13.2 ±0.4 GPa

m

fZ hhBF )(

1

max )(max

m

fhZ hhmB

dh

dFS

A

FH Z max

S

Fhh Z

cmax

max

Contact Stiffness (S):

Hardness (H):

Contact Depth (hc):

Force (Fz) vs. Displacement (h):

A

SEr

2Reduced Elastic Modulus (Er):

Contact Area (A): )( chfA

i

i

r EEE

22 111

Elastic Modulus (E) of the specimen is

calculated using:

where, and i are the Poisson’s ratios of the specimen and the indenter,

respectively; Ei is elastic modulus of the indenter

Bruker Confidential

January 21, 2016 27

Three-point Bend Test

ASTM D790 and ISO:178

Bruker Confidential

Flexural Stress (σf)= 3𝐹𝑍𝐿

2𝑏𝑑2 ;

Flexural Strain (𝜖f) = 6𝐷𝑑

𝐿2

Modulus of elasticity in bending (EB) = 𝐿3𝑚

4𝑏𝑑3

𝑭𝒁

𝑳

𝟐

𝑳

𝟐

𝒃

𝒅

where,

FZ is the force applied; L is the support span

b and d are the width and the depth of the beam, respectively.

D is the maximum deflection at the center of the beam

m is the slope of the initial straight line portion of FZ vs. D plot

January 21, 2016 28


Fz vs. Z plot of a polymer specimen during 3-point bend test

Bruker Confidential

January 21, 2016 29


Flexural Stress vs. Flexural Strain of the polymer specimen

Bruker Confidential

σf = 86 MPa

𝜖f = 0.012

EB = 1.25 GPa

January 21, 2016 30


Bruker Confidential

Fz vs. Z plot of a ceramic specimen during 3-point bend test

January 21, 2016 31


Flexural Stress vs. Flexural Strain of the ceramic specimen

Bruker Confidential

σf = 98 MPa

𝜖f = 0.00072

EB = 13.9 GPa

January 21, 2016 32

Automotive Paints and Coatings

• Paint is relatively thick. Its primary function is to prevent

materials degradation such as corrosion and improve

aesthetic.

• Coating is relatively thin and it is used for enhancing the

tribological properties such as friction, wear, and scratch

resistance of components.

Paints and coating can be evaluated by scratch test.

Substrate

Top Clear Coat (50 m)

Base Coat (20 m)

Primer (25 m)

Electrocoat (25 m)Phosphate Layer (1 m)

Typical Paint System on an Auto body

Bruker Confidential

January 21, 2016 33

Scratch Test Capabilities

o Fully conform to ASTM C1624

o Wide force and velocity ranges for scratching

o Zoom-in option on the scratch image

o Image marker to measure scratch dimensions

o All four (X+, X-, and Y+ and Y-) directional scratching

o Automated positioning, focusing, and imaging of the scratch

o Advanced scratch-imaging options to display and saving of scratch

Image with force, AE, ECR, and depth profile data

o Can accommodate scratch tool such as diamond stylus, Vickers, etc.

o Automatic tilt adjustment during scratch depth profile calculation

Bruker Confidential

January 21, 2016 34

Scratch Tests

Bruker Confidential

(a) Load and (b) scratch width profiles of a Linear scratch;

(c) Load and (d) scratch width profiles of a Zigzag scratch.

(a) (b)

(c) (d)

January 21, 2016 35

Scratch Tests

Bruker Confidential

(a) Load and (b) scratch width profiles of a Unidirectional scratch;

(c) Load and (d) scratch width profiles of a X-Y scratch.

(a) (b)

(c) (d)

January 21, 2016 36

Scratch Adhesion Test of Coating

Scratch test results on painted panels using AE and ECR

Scratch Adhesion Scratched

Bruker Confidential

January 21, 2016 37

Comparative Mar Resistance

Scratch test results using Vickers: Bare Glass A

Mar Resistance: 100 mN

Bruker Confidential

January 21, 2016 38

Comparative Mar Resistance

Scratch test results using Vickers: Bare Glass B

Mar Resistance: 54 mN

Bruker Confidential

January 21, 2016 39

Scratch Test with Depth Profile (Prescan-Scratch-Postscan)

Scratch test results on DLC-coating with a diamond stylus

Bruker Confidential

January 21, 2016 40

Raw-depth profiles of Prescan, Scratch, and Postscan using a

Cap sensor for depth measurements

Bruker Confidential


January 21, 2016 41

Levelled-depth profiles of Prescan, Scratch, and Postscan using

a Cap sensor for depth measurements

Bruker Confidential


January 21, 2016 42

Relative-Scratch depth profiles of Prescan, Scratch, and

Postscan using a Cap sensor for depth measurements

Bruker Confidential


January 21, 2016 43

Summary

o R & D activities are being vigorously pursued by automobile

manufacturers, academia related to automotive, and auto

venders to stand out in the extremely competitive and dynamic

global market. Testing of auto-components for their quality is a

very important activity. UMT TriboLab is leading in such

applications effectively.

o UMT TriboLabTM is built as a universal test system on the

concept of modular and innovative design that covers wide

ranges of test parameters and environmental conditions.

o Integration of Intelligent hardware and software interfaces

makes it extremely user-friendly, most versatile, and very

productive tool for performing tribological and mechanical tests.

Bruker Confidential

January 21, 2016 44

www.bruker.com

[email protected]

Thank you!

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