Formation of Corrugated Damage on Bearing Race under Different AC Shaft Voltages.

Corrugated damage to bearings is a common fault in electrical facilities such as new energy vehicles, wind power, and high-speed railways. The aim of this article is to reveal the microscopic characteristics and formation mechanism of such damages. The corrugation with alternating "light" and "dark" shape was produced on GCr15 bearing races in the experimental conditions. Compared to the light area, the dark area (in the images generated by optical microscope) has more severe electrical erosion, lower hardness, more concave morphology, and lower oxidation. As the voltage increases, the width of the corrugation, the height difference between corrugation, and surface roughness all increase. It is believed that the formation of corrugated damage requires a sufficiently high voltage to induce the periodic destruction and reconstruction of the lubrication film. When the bearing is in a metal-lubrication film-metal contact state, the high voltage causes the lubrication film to break down and induce electrical erosion. Then, the contact area is in metal-metal contact, and the surface is mainly damaged by mechanical rolling. After the reconstruction of lubrication film, the next round of electrical erosion begins. The results are helpful for a deeper understanding of the mechanism of bearing erosion in electrical application.

Velocity-Dependent Friction of Graphene at Electrical Contact Interfaces.

Graphene has enormous potential as a solid lubricant at sliding electrical contact interfaces of micro-/nanoelectromechanical systems that suffer severe wear. Understanding the velocity-dependent friction of graphene under different applied voltages contributes to the application of graphene in sliding electrical contact scenarios. The friction of graphene, measured by conductive atomic force microscopy, under low applied voltage increases logarithmically with sliding velocity─the same as when no voltage is applied but at a faster rate of increase. The variation of friction was explained by the thermally activated Prandtl-Tomlinson model with increased potential barrier and temperature because of the applied voltage. An opposite trend in which friction decreases with sliding velocity is observed under high applied voltage. Topography, adhesion measurements, and SEM characterization demonstrate the wear of the tip. Moreover, the tip wears more severely at low sliding velocity compared to a high sliding velocity. It was interpreted that the excessive Joule heat at the electrical contact interface under high applied voltage weakens the mechanical properties of the tip, resulting in wear and high friction. The increase in the sliding velocity could accelerate the Joule heat transfer and reduce wear and friction. The studies provide beneficial guidelines for the design of graphene-lubricated sliding electrical contact interfaces.

Behavior of Wear Debris and Its Action Mechanism on the Tribological Properties of Medium-Carbon Steel with Magnetic Field.

Friction tests were conducted on self-matched pairs of medium-carbon steel using a pin-disk tribometer in an ambient laboratory environment with and without wear-debris removal, in order to clarify the influence of wear debris on the tribological properties of steels that were exposed to magnetic fields. The wear debris and worn surface were observed and analyzed. In the case that the wear debris was removed, the vast majority of wear debris was large, scarce oxidation, and no agglomeration, the grooves of various shapes and discontinuities, and no oxide layer were formed on the worn surface, severe wear occurred throughout the friction process. When the wear debris was not removed, the wear debris became fine, agglomeration and oxidation, a debris layer was formed on the worn surface, and the wear mode transitioned from severe to mild occurred during friction process. The results reveal that the re-entering of wear debris into the friction area is essential for the formation of a wear-debris layer and that an anti-wear effect can be achieved via the wear-debris layer formed on the worn surface during the friction process with a magnetic field.

Arc Discharges of a Pure Carbon Strip Affected by Dynamic Contact Force during Current-Carrying Sliding.

Arc discharges of a pure carbon strip induced by dynamic contact force were studied on a pin-on-disk tribometer. It was found that arc discharges were produced periodically in accordance with the period of the dynamic contact force. The arcing rate of the pure carbon strip increased with an increase of frequency f and amplitude B, which led to a decrease of current-carrying quality. These influences at high velocities became much more significant. A critical point of the arcing rate at around 2% was detected. Lower than 2%, the pure carbon strip was able to maintain its excellent current-carrying capability; higher than this point, the current-carrying quality deteriorated abruptly. SEM and XPS analysis show that the element Cu detected on the worn surface at lower arcing rates was metal Cu. CuO was found at higher arcing rates. This indicated that the wear mechanism transferred from mechanical wear to arc erosion with the increase of the arcing rate.

Nondestructive tribochemistry-assisted nanofabrication on GaAs surface.

A tribochemistry-assisted method has been developed for nondestructive surface nanofabrication on GaAs. Without any applied electric field and post etching, hollow nanostructures can be directly fabricated on GaAs surfaces by sliding a SiO2 microsphere under an ultralow contact pressure in humid air. TEM observation on the cross-section of the fabricated area shows that there is no appreciable plastic deformation under a 4 nm groove, confirming that GaAs can be removed without destruction. Further analysis suggests that the fabrication relies on the tribochemistry with the participation of vapor in humid air. It is proposed that the formation and breakage of GaAs-O-Si bonding bridges are responsible for the removal of GaAs material during the sliding process. As a nondestructive and conductivity-independent method, it will open up new opportunities to fabricate defect-free and well-ordered nucleation positions for quantum dots on GaAs surfaces.

Maskless micro/nanofabrication on GaAs surface by friction-induced selective etching.

In the present study, a friction-induced selective etching method was developed to produce nanostructures on GaAs surface. Without any resist mask, the nanofabrication can be achieved by scratching and post-etching in sulfuric acid solution. The effects of the applied normal load and etching period on the formation of the nanostructure were studied. Results showed that the height of the nanostructure increased with the normal load or the etching period. XPS and Raman detection demonstrated that residual compressive stress and lattice densification were probably the main reason for selective etching, which eventually led to the protrusive nanostructures from the scratched area on the GaAs surface. Through a homemade multi-probe instrument, the capability of this fabrication method was demonstrated by producing various nanostructures on the GaAs surface, such as linear array, intersecting parallel, surface mesas, and special letters. In summary, the proposed method provided a straightforward and more maneuverable micro/nanofabrication method on the GaAs surface.

Maskless and low-destructive nanofabrication on quartz by friction-induced selective etching.

A low-destructive friction-induced nanofabrication method is proposed to produce three-dimensional nanostructures on a quartz surface. Without any template, nanofabrication can be achieved by low-destructive scanning on a target area and post-etching in a KOH solution. Various nanostructures, such as slopes, hierarchical stages and chessboard-like patterns, can be fabricated on the quartz surface. Although the rise of etching temperature can improve fabrication efficiency, fabrication depth is dependent only upon contact pressure and scanning cycles. With the increase of contact pressure during scanning, selective etching thickness of the scanned area increases from 0 to 2.9 nm before the yield of the quartz surface and then tends to stabilise after the appearance of a wear. Refabrication on existing nanostructures can be realised to produce deeper structures on the quartz surface. Based on Arrhenius fitting of the etching rate and transmission electron microscopy characterization of the nanostructure, fabrication mechanism could be attributed to the selective etching of the friction-induced amorphous layer on the quartz surface. As a maskless and low-destructive technique, the proposed friction-induced method will open up new possibilities for further nanofabrication.

Fabrication mechanism of friction-induced selective etching on Si(100) surface.

As a maskless nanofabrication technique, friction-induced selective etching can easily produce nanopatterns on a Si(100) surface. Experimental results indicated that the height of the nanopatterns increased with the KOH etching time, while their width increased with the scratching load. It has also found that a contact pressure of 6.3 GPa is enough to fabricate a mask layer on the Si(100) surface. To understand the mechanism involved, the cross-sectional microstructure of a scratched area was examined, and the mask ability of the tip-disturbed silicon layer was studied. Transmission electron microscope observation and scanning Auger nanoprobe analysis suggested that the scratched area was covered by a thin superficial oxidation layer followed by a thick distorted (amorphous and deformed) layer in the subsurface. After the surface oxidation layer was removed by HF etching, the residual amorphous and deformed silicon layer on the scratched area can still serve as an etching mask in KOH solution. The results may help to develop a low-destructive, low-cost, and flexible nanofabrication technique suitable for machining of micro-mold and prototype fabrication in micro-systems.

Friction-induced nanofabrication method to produce protrusive nanostructures on quartz.

In this paper, a new friction-induced nanofabrication method is presented to fabricate protrusive nanostructures on quartz surfaces through scratching a diamond tip under given normal loads. The nanostructures, such as nanodots, nanolines, surface mesas and nanowords, can be produced on the target surface by programming the tip traces according to the demanded patterns. The height of these nanostructures increases with the increase of the number of scratching cycles or the normal load. Transmission electron microscope observations indicated that the lattice distortion and dislocations induced by the mechanical interaction may have played a dominating role in the formation of the protrusive nanostructures on quartz surfaces. Further analysis reveals that during scratching, a contact pressure ranged from 0.4Py to Py (Py is the critical yield pressure of quartz) is apt to produce protuberant nanostructures on quartz under the given experimental conditions. Finally, it is of great interest to find that the protrusive nanostructures can be selectively dissolved in 20% KOH solution. Since the nanowords can be easily 'written' by friction-induced fabrication and 'erased' through selective etching on a quartz surface, this friction-induced method opens up new opportunities for future nanofabrication.