A model of the dynamics of boundary film formation

Abstract

The dynamics of formation and loss of the boundary films formed during sliding on steel surfaces were investigated over a range of temperature. Tests are performed on a cylinder-on-disk machine using mineral oil with various concentrations of zinc dialkyldithiophosphate (ZDP). The thickness and refractive index of the boundary films during step load test were monitored in situ with an ellipsometer, and the composition of the films was analyzed by X-ray photoelectron spectroscopy (XPS). As temperature increases, chemical reactivity increases the film formation rate, while the film removal rate increases owing to (a) the decrease of durability of the boundary film material and (b) the reduction of hydrodynamic fluid film thickness due to decreasing viscosity of the lubricant. There is a balance between these two competing mechanisms, and this balance is reflected in the boundary film thickness. The boundary films consist of a film of oxide and metallic compound (OMM) covered by an organo-iron compound (OIC). Their relative effectiveness in preventing scuffing depends on temperature and composition. In particular, the OIC is effective in reducing wear of the opposing surfaces by covering the OMM.