High-speed frictional slip at metal-on-metal interfaces

In this study plate-impact pressure-shear friction experiments are employed to investigate dynamic slip resistance and time-resolved growth of molten metal films during dry metal-on-metal slip under extreme interfacial conditions. By employing a tribo-pair comprising of a hard tool-steel against a relatively low melt-point metal (7075-T6 Al alloy), interfacial normal stress of up to 5 GPa and slip speeds of approximately 250 m/s have been achieved. These extreme interfacial conditions are conducive to the development of molten metal film at the tribo-pair interface. A Lagrangian finite element code is developed to understand the evolution of the thermo-mechanical fields and their relationship to the observed slip response. The code accounts for dynamic effects, heat conduction, contact with friction, and full thermo-mechanical coupling. At temperatures below the melting point of the tribo-pair materials are described as isotropic, thermally softening, elastic–viscoplastic solids. For material elements with temperatures in excess of the melt temperature a purely Newtonian fluid constitutive model is employed.     

Formation of molten metal films during metal-on-metal slip under extreme interfacial conditions

The present paper describes results of plate-impact pressure-shear friction experiments conducted to study time-resolved growth of molten metal films during dry metal-on-metal slip under extreme interfacial conditions. By employing tribo-pairs comprising hard tool-steel against relatively low melt-point metals such as 7075-T6 aluminum alloys, interfacial friction stress ranging from 100 to and slip speeds of approximately have been generated. These relatively high levels of friction stress combined with high slip-speeds generate conditions conducive for interfacial temperatures to approach the melting point of the lower melt point metal (Al alloy) comprising the tribo-pair.A Lagrangian finite element code is developed to understand the evolution of the thermo-mechanical fields and their relationship to the observed slip response. The code accounts for dynamic effects, heat conduction, contact with friction, and full thermo-mechanical coupling. At temperatures below the melting point the material is described as an isotropic thermally softening elastic-viscoplastic solid. For material elements with temperatures in excess of the melt point a purely Newtonian fluid constitutive model is employed.The results of the hybrid experimental-computational study provides new insights into the thermoelastic-plastic interactions during high speed metal-on-metal slip under extreme interfacial conditions. During the early part of frictional slip the coefficient of kinetic friction is observed to decrease with increasing slip velocity. During the later part transition in interfacial slip occurs from dry metal-on-metal sliding to the formation of molten Al films at the tribo-pair interface. Under these conditions the interfacial resistance approaches the shear strength of the molten aluminum alloy under normal pressures of approximately 1- and shear strain rates of . The results of the study indicate that under these extreme conditions molten aluminum films maintain a shearing resistance as high as .Scanning electron microscopy of the slip surfaces reveal molten aluminum to be smeared on the tribo-pair interface. Knoop hardness measurements in 7075-T6 Al alloy at various depths from the slip interface indicate that the hardness increases approximately linearly with depth and reaches a plateau at approximately from the surface.     

A modified torsional kolsky bar for investigating dynamic friction

This paper introduces an experiment to investigate dry sliding resistance of frictional interfaces at normal pressures up to 100 MPa, slip speeds up to 10 m/s and slip distances of approximately 10 mm. This new apparatus involves a novel modification of the conventional torsional Kolsky bar apparatus, employed extensively in the past for investigating high strain rate behavior of engineering materials. The new experimental configuration represents a significant improvement over conventional tribology experiments because it uses elastic torsional waves with a superimposed static compressive force to control the interfacial traction. Moreover, the apparatus allows critical frictional parameters such as the interfacial sliding resistance, slip speeds and slip without the use of transducers at the frictional interface. The usefulness of the device is demonstrated by presenting results of high-speed friction on 6061-T6 Al/1018 steel and Carpenter Hampden tool steel/7075-T6 Al tribo pairs.     

A pressure-shear plate impact experiment for investigating transient friction

A pressure-shear plate impact experiment is introduced to study time-resolved friction at interfaces subjected to high sliding speeds under relatively high normal pressures. The conditions of slip at the interface are varied by changing the surface roughness of the impacting plates and by varying the applied normal to shear stress ratio. The configuration offers the simplicity of allowing the interpretation of the experimental data by using the frame-work of one-dimensional plane wave analysis. The interfacial material pairs investigated in the present study are comprised of a wear-resistant grade of tungsten carbide and either an AISI 4340 steel or a Ti-6AI-4V alloy. The experimental results indicate that the coefficient of friction increases with the increase in surface roughness of the tungsten-carbide plates and with cumulative slip at the interface.     

Slip weakening in rocks and analog materials at co-seismic slip rates

Determination of co-seismic slip resistance in earth faults is critical for understanding the magnitude of shear-stress reduction and hence the near-fault acceleration that can occur during earthquakes. Also, knowledge of shear resistance dependency on slip velocity, slip distance, normal stress, and surface roughness is fundamental information for understanding earthquake physics and the energy released during such events. In the present study, plate-impact pressure-shear friction experiments are employed to investigate the frictional resistance in fine-grained Arkansas novaculite rock and an analog material (soda-lime glass), under relevant interfacial conditions. The results of the experiments indicate that a wide range of frictional slip conditions can exist during a single slip event. These conditions range from initial no-slip followed by slip weakening, strengthening, and seizure at the frictional interface. For the case of glass vs. glass experiments, the first slip-weakening, with μ in the range of 0.4-0.2, is understood to be most likely due to thermal-induced flash heating and incipient melting at asperity junctions, while the slip-strengthening, with μ in the range of 0.1-0.4, is understood to be a result of coalescence and solidification of local melt patches. For the case of the fine grain Arkansas Novaculite rocks a similar range of slip conditions is observed.     

High-temperature pressure-shear plate impact experiments using pure tungsten carbide impactors

The pressure-shear plate impact experiment has been modified to test materials at high temperatures (up to 700°C). Together with the high strain rates characteristic of this experiment (10⁶ s^–1), the high-temperature capability allows the shearing resistance of materials to be measured under conditions unattainable with other testing equipment. The compressive and shear responses of pure tungsten carbide at different temperatures are presented, as well as the results of one test on OFHC copper at a temperature of 691°C and a shear strain rate of 1.4×10⁶ s^–1.     

In Situ Observation of Adiabatic Shear Band Formation in Aluminum Alloys

We used high-speed X-ray phase contrast imaging and infrared thermal imaging techniques to study the formation processes of adiabatic shear bands in aluminum 7075-T6 and 6061-T6 alloys. A modified compression Kolsky bar setup was used to apply the dynamic loading. A flat hat-shaped specimen design was adopted for generating the shear bands at the designated locations. Experimental results show that 7075-T6 exhibits less ductility and a narrower shear band than 6061-T6. Maximum temperatures of 720 K and 770 K were locally determined within the shear band zones for 7075-T6 and 6061-T6 respectively. This local high temperature zone and the resulting thermal instability were found to relate to the shear band formation in these aluminum alloys.

     

Wall slip and melt fracture of poly(lactides)

The wall slip and melt fracture behaviour of several commercial polylactides (PLAs) as well as their rheological properties under shear and extensional have been investigated. The PLAs have had weight-average molecular weights in the range of 10⁴–10⁵ g/mol and studied in the temperature range of 160–200°C. The solution properties and linear viscoelastic behaviour of melts indicate linear microstructure behaviour. PLAs with molecular weights greater than a certain value were found to slip, with the slip velocity to increase with decrease of molecular weight. The capillary data were found to agree well with linear viscoelastic envelope once correction for slip effects was applied. The onset of melt fracture for the high molecular weight PLAs was found to occur at about 0.2 to 0.3 MPa, depending on the geometrical characteristics of the dies and independent of temperature. Addition of 0.5 wt.% of a polycaprolactone (PCL) into the PLA that exhibits melt fracture was found to be effective in eliminating and delaying the onset of melt fracture to higher shear rates. This is due to significant interfacial slip that occurs in the presence of PCL.     

Tensile testing of materials at high rates of strain

A tension version of the split Hopkinson bar or Kolsky apparatus is developed for conducting tests in tension at high rates of strain up to 10³ s^?1. A number of aluminum, titanium, and steel alloys tested in tension show increasing degrees of rate sensitivity above 10 to 10² s^?1. Tests on 6061-T651 and 7075-T6 aluminum show measurable strain-rate sensitivity in tension at the highest strain rates, although similar tests in compression in the literature show essentially no strain-rate sensitivity. Details of the apparatus and instrumentation and guidelines for its use are presented.     

Development of a New Method to Investigate the Dynamic Friction Behavior of Interfaces Using a Kolsky Tension Bar

To understand interfacial interaction of a bi-material during an impact loading event, the dynamic friction coefficient is one of the key parameters that must be characterized and quantified. In this study, a new experimental method to determine the dynamic friction coefficient between two metals was developed by using a Kolsky tension bar and a custom-designed friction fixture. Polyvinylidene fluoride (PVDF) force sensors were used to measure the normal force applied to the friction tribo pairs and the friction force was measured with conventional Kolsky tension bar method. To evaluate the technique, the dynamic friction coefficient between 4340 steel and 7075-T6 aluminum was investigated at an impact speed of approximately 8 m/s. In addition, the dynamic friction coefficient of the tribo pairs with varied surface roughness was also investigated. The data suggest that higher surface roughness leads to higher friction coefficients at the same speed of 8 m/s.     

Change in the electrical resistance of the friction zone of metal composites with the addition of a Pb-Sn melt

Volt-ampere characteristics of the sliding zone of steel-base metal composites in a current collection mode are presented. Friction is implemented at a current density of 100 A/cm² for the cases of absence and presence of a Pb-Sn melt in the friction zone. An elementary model of rough surface contact is proposed to assess the relation between the area occupied by the melt and the current density. It is shown that the addition of molten low-melting metals is an effective way to reduce the electrical resistance of the friction zone of sliding electrical contact.     

Use of a sliding plate rheometer to measure the first normal stress difference at high shear rates

The use of a sliding plate rheometer (SPR) to determine the first normal stress difference of molten polymers and elastomers at high shear rates is demonstrated. The simple shear flow in this instrument is not subject to the flow instabilities that limit the use of rotational rheometers to shear rates often below 1 s⁻¹. However, issues of secondary flow and wall slip must be addressed to obtain reliable data using an SPR. A highly entangled, monodisperse polybutadiene and a commercial polystyrene were the polymers studied. The inclusion of the polystyrene made it possible to compare data with those obtained by Lodge using a stressmeter, which is an instrument based on the measurement of the hole pressure. The data from the two instruments are in good agreement and are also close to the predictions of an empirical equation of Laun based on the storage and loss moduli.     

Stress-induced interfacial failure in filled polymer melts

We study a dynamic interfacial slip phenomenon in filled polymer melts. When a poly(dimethyl siloxane) melt of weight average molecular weight M _w = 93 700 is mixed with glass beads of diameter up to 45 m, the sample shows some evidence of breakdown of interfacial adhesion between the glass beads and the PDMS matrix at a level of oscillatory stress under which the pure PDMS melt exhibits no decay. The decay of viscoelastic properties with time is essentially independent of the amplitude of shear strain as long as the magnitude of the oscillating stress is sufficiently high. It is suggested that much higher local stress than the apparent applied stress may be generated between the narrowly spaced beads. The interfacial slip was observable because it was measured against a natural length scale d in the filled polymer melts which is the filler size or the inter-filler distance and is much smaller than the dimensions of the flow cell. The decay under high stress and healing of interfacial adhesion upon a large reduction in stress may be related to the de-bonding and reformation of hydrogen bonds between the PDMS chains and the glass bead surfaces.     

Dual hologram shearing interference technique for wind tunnel flow fields testing

 A novel optical diagnostic technique, dual hologram shearing interferometry, for measuring density gradients of different phase objects is proposed and demonstrated. The lateral shearing is achieved by using a phase grating. A holographic interferometer has been developed and designed on the base of a single pass Z type conventional schlieren device. The interferometer’s scheme is insensitive to acoustical disturbances, similarly to the conventional schlieren layout, and is capable of recording holograms with a continuous wave laser during the wind tunnel run. The features of the technique make it tolerant to both the temporal coherence of the laser light source and to the relatively low, schlieren quality optical windows of the wind tunnel’s test section. The obtained reconstructed lateral shearing interferograms with a large region of overlap have high contrast and may have an arbitrary orientation and/or spacing of the background interference fringes. It is believed that the proposed approach will become a useful tool for visualization and accurate mapping of the density gradients of gas dynamic flow fields, in wind and shock tunnels, where acoustic noise problems may dramatically affect reference beam holographic schemes. Received: 9 January 1997 / Accepted: 12 April 1997     

Simultaneous determination of shear and extensional viscosities and wall slip by on-line rheometry with parameter fitting: an application to EPDM rubber

Shear and extensional viscosities and wall slip are determined simultaneously under extrusion processing conditions using an on-line rheometer. Because it is not possible to independently control flow rate and temperature, classical methods for interpretation of capillary data cannot be used with on-line rheometry. This limitation is overcome using computational optimization to fit parameters in a flow model. This consists of three parts, representing shear viscosity, extensional viscosity, and wall slip. Three-parameter, power law forms, based on local instantaneous deformation rates and including temperature dependence, are used for each, and analytic solutions applied for entry flow and flow in the capillary. For entry flow, the Cogswell–Binding approach is used, and for developed flow in the capillary a solution incorporating wall slip is derived. The rheometer, with interchangeable capillaries, is mounted in place of the die on a rubber profile extrusion line. Pressure drops and temperatures for extrusion of an EPDM rubber through 2 mm diameter capillaries of length 0, 2, 3, 4, and 5 mm are logged and flow rates determined for a range of extruder speeds (5 to 20 rpm). Pressures ranged from 60 to 75 bar and temperatures from 86 to 116 °C. Mean flow velocity in the capillaries was between 5 × 10⁻³ and 5 × 10⁻¹ m s⁻¹. The nine material parameters are optimized for best fit of the analytic pressure drops to experimental data, using about 100 data points, with the Levenberg–Marquardt method. It is concluded that flow is dominated by extension and wall slip. Shear flow appears to play little part. The slip model indicates that slip velocity increases much more rapidly than the wall shear stress (in the range 0.5–1 MPa) and decreases with temperature for a given stress level. Results for the (uniaxial) extensional viscosity represent an engineering approximation to this complex phenomenon at the high strains (approximately 200) and high extension rates (up to 800 s⁻¹) applying in the extrusion. Results indicate a slight extension hardening and a decrease with temperature. Results are put into the context of the available studies in the literature, which, particularly with regard to wall-slip and extensional flow, consider conditions far removed from those applying in industrial extrusion. The present methods provide a powerful means for flow characterization under processing conditions, providing data suitable for use in computer simulations of extrusion and optimization of die design.     

Elastic properties of polyethylene melts at high shear rates with respect to extrusion

At high shear rates a steady state of shear flow with constant shear rate, constant shear stress, and constant recoverable shear strain is observed in the short-time sandwich rheometer after some few shear units already. The melt exhibits rather high elastic shear deformations and the recovery occurs at much higher speed than it is observed in the newtonian range. The ratio of first normal stress difference and twice the shear stress, being equal to the recoverable strain in the second-order fluid limit, significantly underestimates the true elastic shear strains at high shear rates. The observed shear rate dependence of shear stress and first normal stress difference as well as of the (constrained) elastic shear strain is correctly described on the basis of a discrete relaxation time spectrum. In simple shear a stick-slip transition at the metal walls is found. Necessary for the onset of slip is a critical value of shear stress and a certain amount of elastic shear deformation or orientation of the melt.     

How polymeric solvents control shear inhomogeneity in large deformations of entangled polymer mixtures

This work aims to elucidate how molecular parameters dictate the occurrence of inhomogeneous cohesive failure during step strain and large amplitude oscillatory shear (LAOS) respectively in entangled polymer mixtures. Based on three well-entangled polybutadiene (PB) mixtures, we perform simultaneous rheometric and particle-tracking velocimetric (PTV) measurements to illustrate how the slip length controls the degree of shear banding. Specifically, the PB mixtures were prepared using the same parent polymer (M _w ∼ 10⁶ g/mol) at 10 wt.% concentration in respective polybutadiene solvents (PBS) of three different molecular weights 1.5, 10, and 46 kg/mol. After step strain, the entangled PB mixture with PBS-1.5 K displayed interfacial failure whereas the PB mixture with PBS-10 K showed bulk failure, demonstrating the effectiveness of our strategy to suppress wall slip by controlling PBS’ molecular weight. Remarkably, the PBS-46K actually allows the elastic yielding to occur homogeneously so that no appreciable macroscopic motions were observed upon shear cessation. PBS is found to play a similar role in LAOS of these three PB mixtures. Finally, we demonstrate that in case of the slip-prone mixture based on PBS-1.5 K the interfacial failure could be drastically reduced by use of shearing plates with considerable surface roughness.     

Investigation on the plastic work-heat conversion coefficient of 7075-T651 aluminum alloy during an impact process based on infrared temperature measurement technology

The plastic work-heat conversion coefficient is one key parameter for studying the work-heat conversion under dynamic deformation of materials. To explore this coefficient of 7075-T651 aluminum alloy under dynamic compression, dynamic compression experiments using the Hopkinson bar under four groups of strain rates were conducted, and the temperature signals were measured by constructing a transient infrared temperature measurement system. According to stress versus strain data as well as the corresponding temperature data obtained through the experiments, the influences of the strain and the strain rate on the coefficient of plastic work converted to heat were analyzed.The experimental results show that the coefficient of plastic work converted to heat of 7075-T651 aluminum alloy is not a constant at the range of 0.85–1 and is closely related to the strain and the strain rate. The change of internal structure of material under high strain rate reduces its energy storage capacity, and makes almost all plastic work convert into heat.     

A physically-based,quasilinear viscoelasticity model for the dynamic response of polyurea

Polyurea, a promising material for damage mitigation in impact scenarios, has been investigated through plane-wave, pressure-shear plate impact (PSPI) experiments to obtain its mechanical response at high pressures and high strain rates. Based on these experimental results, a physically-based, quasi-linear, viscoelasticity model is introduced to capture the observed nonlinear pressure-volume behavior, the strong dependence of shearing resistance on pressure, and the strong relaxation of deviatoric stresses. This model has been implemented in finite element software ABAQUS to simulate the response of polyurea P1000 under the impact conditions of a variety of PSPI experiments. Simulation results agree reasonably well with those of the experiments.