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Tribological behaviour of an electrochemical jet machinedtextured Al-Si automotive cylinder liner material

Walker, J.C.; Kamps, T.J.; Lam, J.W.; Mitchell-Smith, Jonathon; Clare, Adam T.

Authors

J.C. Walker

T.J. Kamps

J.W. Lam

Jonathon Mitchell-Smith

ADAM CLARE adam.clare@nottingham.ac.uk
Professor of Manufacturing Engineering



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 2.3 mol 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.

Citation

Walker, J., Kamps, T., Lam, J., Mitchell-Smith, J., & Clare, A. T. (2017). Tribological behaviour of an electrochemical jet machinedtextured Al-Si automotive cylinder liner material. Wear, 376-377(B), 1611-1621. https://doi.org/10.1016/j.wear.2017.01.085

Journal Article Type Article
Acceptance Date Jan 23, 2017
Online Publication Date Jun 15, 2017
Publication Date Apr 15, 2017
Deposit Date Jan 27, 2017
Journal Wear
Print ISSN 0043-1648
Electronic ISSN 1873-2577
Publisher Elsevier
Peer Reviewed Peer Reviewed
Volume 376-377
Issue B
Pages 1611-1621
DOI https://doi.org/10.1016/j.wear.2017.01.085
Keywords Surface Texturing; Automotive; Al-Si; Friction; Wear; Electrochemical Jet Machining
Public URL http://eprints.nottingham.ac.uk/id/eprint/40140
Publisher URL https://www.sciencedirect.com/science/article/pii/S0043164817302168
Copyright Statement Copyright information regarding this work can be found at the following address: http://creativecommons.org/licenses/by/4.0