| Some typical applications where scuffing may occur are gear teeth, piston rings and cylinder pairs, cams and followers, splines, sleeve bearings, and parts of swash and wobble plate compressors. Unlike other tribology-related failures, scuffing occurs very fast, without any warning, and usually leads to the complete destruction of the sliding pair. Practical experience with steel has helped to outline safe ranges of operation for some components. Very little, however, is known about aluminum, which is the second most commonly used engineering metal. The aim of this study is to obtain a better understanding scuffing and seizure of aluminum/steel contacts.;The research includes an experimental study of scuffing of aluminum/steel contacts under dry sliding conditions, a study of the physics of the scuffing process, evaluation of various hypotheses for scuffing, and modeling of scuffing.;The experiments are conducted in a custom-designed tribometer, which provides accurate control of the environmental conditions. Special instrumentation, experimental procedures and software are developed as a part of the experimental program. These provide a reliable reproduction and identification of scuffing under laboratory conditions. The scuffing characteristics of five materials are obtained in air and refrigerant (R134a) environments. The effects of load, sliding velocity, mechanical strength, environmental temperature, specimen geometry, time, loading history, and type of environment are evaluated.;The mechanisms leading to scuffing are studied by examination of surfaces, subsurfaces and wear debris of specimens in the process of scuffing. Quantitative measurements of subsurface plastic strain are also obtained.;The theoretical part of the study includes the development of a finite element model for the contact of runned-in rough surfaces and several other models for subsurface stresses, temperatures, and strains. These models provide information about the local conditions in the subsurface.;Based on the experimental observations and the scuffing models a new hypothesis for scuffing is proposed. According to this hypothesis, scuffing involves initiation of cracks due to subsurface plastic deformation, propagation of these cracks leading to the removal of the existing protective surface layers, and finally cold welding due to adhesion between bare metal surfaces. |
