Wear - Elsevier Sequoia S.A.

, Lausanne - Printed in the Netherlands

TESTING MACHINES TO STUDY FRETTING WEAR*

.I. G;iNSHEIMER AND G. FRIEDRICH

Research and Development Department, Dow Corning GmbH, Munich (Germany)
(Received October 20, 1970; in revised form December 18, 1970)

SUMMARY

Four testing machines developed to study fretting are useful tools for lubricant
development to minimize fretting wear. Test results are presented on greases, solid
lubricant pastes, solid lubricant powders, bonded coatings, and mineral oils. The
parameters which influence the test results of these four fretting testing machines are
discussed.

INTRODUCTION

Oscillations of small amplitude and high frequency caused either by an out-

side influence or by a design function often occur on machines in industry. Such oscilla-
tions may take place in a vertical, longitudinal or torsional direction of motion to the
surface (Fig. 1). Fretting wear occurs under these conditions and lubricants are re-
quired which prevent or reduce this type of wear. Most lubricant testing machines
operate under unidirectional motion and testing machines which simulate oscillating
motions in actual machines in industry are required.

MECHANISM OF FRETTING WEAR

Fretting wear occurs on surfaces sliding on each other under oscillating motion
of low amplitude and high frequency. On steel surfaces reddish-brown deposits may
be observed (Fig. 2), which eventually cause seizure and failure. Thus it is important
to investigate the mechanism of fretting wear in order to develop lubricants which
eliminate or reduce it. Surface study is essential in such an investigation.
Surface waviness and roughness, even on the most accurately machined sur-
faces (Fig. 3), are still large enough to prevent contact over the entire bearing area of
two mating surfaces. Real contact occurs only at a few high spots of the surfaces, and
even under low load the pressure on these spots will exceed the yield pressure of the
metal and plastic deformation will result. This plastic deformation continues until the
real area of contact is large enough to carry the applied load.

l Paper presentedat the Symposium on “Lubricant Test Devices and their Relation to Service Conditions”,
Second International Conference, Paisley College of Technology, Paisley, Renfrewshire, Scotland, Septem-
ber 7-11. 1970.

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408 J. GANSHEIMER. G. FRIEDRICH

Fig. 1. Different types of oscillating motions.

TABLE I

EXAMPLES OF TRIBOCHEMICAL REACTIONS

Enthalpy of Free energy of

reaction (AH) reaction (AC)

Ni+4CO=Ni(CO), -39.1 - 1.48

Ni+iO,=NiO - 59.3 -51.8
analogue : Al, Mg, Sb, As, Cr, Fe, Si
Fe+H,O=Feoxide+H, -35.8 -24.0
C+2HzO=COZ+2H2 +21.5 + 14.9
Ni+CO=NiO+C - 32.9 - 19.0
2Ni+CO,=2NiO+C - 14.6 - 1.4
2co=co,+c -41.2 - 28.63
SIC + 2HZ = Si + CH, - 8.8 + 14.0
C+2H,=CH, - 17.9 - 12.1
Fe,C+2H,=3Fe+CH, -22.9 -15.6
Ca+H,=CaH, -45.1 -35.8
BaO,=BaO+fO, + 17.1 +13.2
3Fe+C=Fe,C + 5.0 f 3.5
Ni+H,S=NiS+H - 14.4 -
2
2H,+02=2H,0 - 57.8 - 54.6
C,H6+3HZ=CsH,, -49.3 - 23.4
N,+3HZ=2NH, -11.1 - 4.0

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TESTING MACHINE TO STUDY FRETTING WEAR 409

During plastic deformation, a high potential energy is created in the surface

layer as in this layer the metal atoms are moved into a higher energy level than they
were originally. This high potential energy becomes free in the presence of reactive
substances and chemical reactions occur such as the oxidation of iron with oxygen.
2 Fe + 13 O2 -+ Fe, O3 (1)
More than a hundred chemical reactions (tribochemical reactions, as they are
called) have been observed and measured quantitatively. Examples are shown in
Table I ‘.

Fig. 2. Fretting wear on the eccentric shaft of screening equipment for gravel.

From the facts outlined, reasons for the severity of fretting wear may be deduc-
ed:
(a) A reaction between iron and oxygen according to eqn. (1) gives a volume per
weight unit of iron oxide much larger than of iron ; 1.43 g Fe,OJ are formed from 1 g
Fe, which due to the lower density of iron oxide compared to that of iron is 2.22 cm3 of
FezOX from 1 cm3 Fe.
This increase of volume of wear debris may cause the machine element to stall.

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410 J. GiNSHEIMER, G. FRIEDRICH

(b) The oscillatory nature of frictional movement which leads to fretting wear
is not the primary cause of wear, which occurs also under unidirectional motion.
However, under oscillatory motion of low amplitude new lubricant cannot easily
penetrate into the friction area. Therefore the chemical reaction products formed can-
not be removed from the friction area by the lubricant. Also, one function of a lubri-
cant, removal of heat, is not very effective under oscillating conditions.

Fig. 3. Technical surfaces in sliding contact. Ground steel surface, surface roughness Ra = 0.2 pm. ( x 2300)

(c) The hardness of oxidized wear particles is often higher than that of the
original metal from which they are formed. The wear debris thus acts as abrasive and
surface damage may be severe.
(d) The lubricant initially present at the friction area may also participate in
the chemical reactions. It can also be decomposed by oxidation. The decomposition
and the reaction products of the lubricant contribute to the fretting damage.

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TESTING MACHINES TO STUDY FRETTING WEAR 411

FRETTING WEAR IN PRACTICAL APPLICATIONS

In the literature2-5 distinction is made between oscillations which occur

where relative motion was not intended, and oscillations occurring on parts which are
meant to carry out a relative motion either occasionally or during the whole operation
period. This distinction is very arbitrary and without physical significance, as con-
ditions for damage and type of damage are the same in both cases.
Thus oscillations created by outside causes can be the origin of fretting cor-
rosion. For example, oscillation of the foundation can create fretting corrosion on
machines in the workshop; vibrations of a diesel engine of a ship can create fretting
wear on equipment being shipped, etc. The example of cars which were forwarded by
rail from Detroit to the west coast of America is often cited. The bearings suffered
more damage during this short time than would have been the case after 100,000 miles
of normal driving.
Fretting also occurs on threaded connections and rivet joints, on press fits or
spline connections, on electric switches of machines and on wire ropes, which often are
subjected to vibration.
Besides externally caused vibratory motion, oscillations which occur on
machines during operation are often the cause of fretting wear, for example, clutches,
infinitely variable gears or bearings which are subject to oscillating motion, flat spring
systems, vibrators and ball joints.
From data published in the literature6-9, the conditions under which fretting
has been tested with about 20 different test instruments are listed in Table II.
Despite these investigations, which on the whole are extensive but often very
limited, the evidence produced is non-uniform and often contradictory.

TABLE II

RANGE OF TEST CONDITIONS OF FRETTING TESTING MACHINES

Frequency : l-lO,C@O Hz Load : 20 g-10,000 kg

Amplitude
: 100 A-7 cm Test time: @10x 10’ osc.

Inf7uence of the load

Many report that an increase of load increased the fretting wear damage”- 15,
others have determined that load has no influence on the damage’4,‘6-‘9. When
sliding motion is eliminated by increasing the load, fretting damage can be prevented.

Influence of the amplitude

Generally, it has been established that increase of amplitude increases the
damage 8320. But it has also been found that the highest wear occurs at medium
amplitude10*2’,22.

Influence of the frequency

It has usually been observed that the frequency has no influence on the fretting
wear23,24. But it has been reported that damage decreases with increasing frequency7,20
and also that damage increases with increasing frequency25-27.

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412 J. GiNSHEIMER, G. FRIEDRICH

Influence of test duration

Here the statements are naturally indisputable: the wear increases with increase
of time.

Other influences
Statements concerning the influence of temperature, the presence of oxygen,
the influence of humidity, metal combination, and the type of lubricant, are similarly
confusing. It is reported that low viscosity oils are more effective in preventing
fretting wear than high viscosity oils’o,1 ‘,l 3,28 and that thick oils are more advan-
tageous than thin ones 22 It is reported that the decisive criterion is the adhesive
strength of the oils28-30.
The contradictory statements on the basis of previous tests show that it is
necessary for the producer of lubricants to carry out tests using various testing
machines, and to correlate the results with service tests.
This paper reviews the testing machines which we have developed to study
fretting wear on this basis*.

TESTING MACHINES

In the SRV (Schwingungsreibverschleiss) testing machine, Fig. 4, an upper

test specimen is pressed at constant load exerted by a magnet against the end surface
of a fixed cylinder. An oscillating magnet produces a back and forth motion on the
upper test specimen. The amplitude of this motion, which is a function of the friction

Prlnctple of Operation : 5RV Testing MacMne

Fig. 4. SRV testing machine. Principle of operation.

* These testing machines have been developed and/or modified in the Testing Department of Dow Corning
GmbH in Munich by A. A. Bartel and A. Sedlmair.

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TESTING MACHINES TO STUDY FRETTING WEAR 413

Fig. 5. LFW-1 testing machine. Principle of operation.

Fig. 6. AxiaI oscillating ball bearing tester. Principle of operation.

between the test specimens, is shown on the oscilloscope. If the friction becomes
‘too high the motion of the test specimen stops and the amplitude goes to zero. The
period of time between the start and the end of the motion and the height of the
amplitude at the beginning of the test are the criteria for lubricant performance.
In the LFW-1 testing machine, Fig. 5, an infinitely variable drive motor with
an eccentric crank moves the shaft into oscillatory motion, the arc of which can be
varied. A Timken ring is mounted on the cone of the shaft, so that it rotates with the
shaft. A self-aligning stationary block is stepwise loaded against the ring. Friction
force can be continuously measured by a load cell and recorder. The criteria for
lubricants is the number of oscillations until a preselected coefficient of friction is
reached.
The axial oscillating ball bearing tester (modilied Fafnir), Fig. 6, contains a
housing in which a plate spring presses against the axial ball bearing with a constant
load. In this bearing the upper ring is fixed whereas the bottom ring oscillates through

Wear, 17 (1971)407~19
 J. G;iNSHEIMER, G. FRIEDRICH

Fig. 7. Ball joint testing machine. Principle of operation.

an eccentric drive powered by a constant speed electric motor. The oscillating arc can
be varied by changing the eccentricity of the drive shaft. The test criteria is determined
by the amount ofwear and the appearance of the wear track after 2 million oscillations.
In the ball joint testing machine, Fig. 7, four commercial automotive ball
joints, having a preapplied constant load, are filled with the grease to be tested and
mounted in the testing machine. Superimposed on the ball joint are two oscillating
motions: a slow rotational plus a fast longitudinal motion, Both are driven from an
electric motor; the first by a chain drive, the second by a cam drive. Test criteria are
the amount of wear in mg and the appearance of the sliding surface after 25 million
oscillations.
These four testing machines have one common function, oscillating motion
under load, but the testing conditions differ greatly. In all cases tests furnish only a
few absolute data such as the coefficient of friction from the LFW-1 and the amount
of wear (in mg) from the axial ball bearing oscillator and the ball joint testing machine.
But for lubricant development testing under conditions simulating practical applica-
tion leads to better and faster results than testing only under extreme laboratory
conditions.
A comparison of the various parameters of these four testing machines is
shown in Table III.

TEST RESULTS

Table IV presents comparative data of three different lubricating oils on the

SRV and the axial oscillating ball bearing testing machines. Oils A and B are mineral

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TESTING MACHINES TO STUDY FRETTING WEAR 415

TABLE III

DATA OF TESTING MACHINES TO STUDY FRETTING WEAR

Testing SRV LFW-1 oscillating Axial ball bearing Ball joint

machines :

Type of contact Area line point Line area Point Area

F
Specimen
configuration fi* * F

Frequency 50 Hz 0.1515 Hz variable 22.1 Hz 22.7 Hz longitudinal

osc.
Hz rotational 03
Amplitude IX1 mm Function of l&90 deg of arc l-30 deg of arc oscillatory longitudil
lubricant motion, l-10 mm; v
able oscillatory rota
tional motion, 4&6(
of arc
Load 5-80 kg variable 13-286 kg variable 400 kg 60 kg
Testing time &20 min depending depending on lubricant 24.5 h=2 x IO6 306h=25x106
on lubricant oscillations oscillations
Type of friction sliding sliding rolling sliding
Data being a) Amplitude at the a) Coefficient of a) Wear (mg) a) Wear of the ballpi
measured beginning of test friction b) Appearance of (mg)
(pm) b) Endurance time of wear track b) Appearance of bal
b) Time to breakdown lubricant film pin surface
of lubricating film c) Temp. in the test
(set) block
Lubricants Greases, oils, pastes, Bonded coatings, Greases, pastes, Greases
which can be bonded coatings, pastes, powders, oils
tested powders oils
Other possible Change of surround- Change of surround- Presence of water
test conditions ing atmosphere ing atmosphere or salt water
(gases, vapours, (gases, vapours,
humidity), tempera- humidity), tempera-
ture and test specimen ture and test specimen
composition composition

oils and C is a synthetic ester oil, the viscosity of B being higher than that of A.
The test data indicate that both viscosity and chemical composition determine
the behaviour of the oil against fretting wear.
Table V shows comparative data of three greases on three testing machines
the ball joint, axial oscillating ball bearing and the SRV testing machine. All three
greases are based on mineral oil and have the same eenetration and bleeding char-
acteristics but contain different chemical EP-additives. Again, a good correlation of
results on the various testing machines can be observed.
In Table VI test results are given for three different solid lubricant pastes.
Paste C, a combination of metal powders (Al + Cu) in mineral oil, gave the poorest
performance under oscillating motion. Products of this type are often used for the
lubrication of threaded connections at high temperatures. The second best per-
formance was given by paste B, a combination of graphite and MoS, in mineral oil.

Wear, 17 (1971) 407419

416

TABLE IV

EVALUATION OF LUBRICATING OILS IN THE SRV AND AXIAL OSCILLATING BALL BEARING TESTER

Test conditions SRV Axial oscillating

ball bearing

Frequency 50 Hz 22.1 Hz
Amplitude 12”
Load 45 kg 400 kg
Testing time 24.5 h =2 x lo6 osc.
Test specimen composition Both specimens roller bearing Axial ball bearing
steel 51203
Surface roughness 0.05-0.1 nm 0.6 itm
(Ra, DIN 4763)

Lubricant composition Viscosity Test criteria

Amplitude at Endurance Wear

beginning of time (ms)
test (pm) (set)

Oil A mineral oil 43.1 cSt/50°C 500 11.5 0

Oil B mineral oil 60.8 cSt/SO’C 500 7.5 0.45
Oil C ester oil 11.2 cSt/50”C 200 2.25 4.3

TABLE V

EVALUATION OF LUBRICANT GREASES IN THE BALL JOINT, AXIAL OSCILLATING BALL BEARING AND SRV TESTING

MACHINES

Test conditions Ball joint Axial oscillating SRI/

ball bearing

Freauencv
a ,
22.7 Hz. 0 Hz 22.7 Hz 50 Hz
Amplitude 40°C 12°C
Load 60 kg 4M) kg 45 kg
Testing time 306 h=24x lo6 osc. 24.5 h = 2 x lo6 osc. ~-
Test specimen ’ Steel against Axial ball bearing Roller bearing steel
composition fluorolastomer 51203
Surface roughness
(Ra, DIN 4763) Ra=0.8 pm Ra = 0.6 pm Ra = 0.050.1 nm

Lubricant Penetration Test criteria

(h mm )

Wear Wear track Wear Amplitude at Endurance

(ms) appearance (ms) ’ beginning of time
test (pm) (set)

Grease A 270 7 No change visible 0.9 400 24

Grease B 270 13 Small scratches 5.1 400 20
Grease C 270 16 Dark brown spots 17.1 400 16
on surface

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TESTING MACHINES TO STUDY FRETTING WEAR 417

TABLE Vl

EVALUATION OF SOLID LUBRICANT PASTES IN THE AXIAL OSCILLATING BALL BEARING, SRV, AND LFW-1
TESTING MACHINES

Test conditions Axial oscillating SRV LFW-1

ball bearing oscillating

Frequency 22.1 Hz 50 Hz 1.5 Hz

Amplitude 12°C 90°C
Load 400 kg 45 kg 90 kg
Testing time 24.5 h=2 x lo6 osc.
Test specimen composition Axial ball bearing Roller bearing steel Steel,
51203 4620 AISI
(SAE) 01
Surface roughness Ra = 0.6 pm Ra=0.05-0.1 pm Ra = 0.2 pm
(Ra, DIN 4763)
Coefficient of friction 0.08

Lubricant composition Test criteria

Wear Amplitude at Endurance time

(md beginning of (no. of
test (pm) (set) oscillations)

Paste A mineral oil + 0.2 >lOOO 24 126000

MoS, + inorg. phosphates
Paste B mineral oil + 19.6 1000 13 18000
MoS, + graphite
Paste C mineral oil + 23.2 < 100 <l 9000
Cu+Al

Paste A, a new development, a combination of MoS, with inorganic phosphates,

gave the best performance.
Table VII shows the comparison of dry solid lubricant films on the SRV and
the LFW-1 testing machines. Bonded coating A, a combination of inorganic binders
plus MoS,, shows the highest endurance life on both testing machines, 124,000
oscillations on the LFW-1 and 31.5 set on the SRV, the amplitude being 1000 ,um.
Powder A, which is MoS, powder microsize (particle size 2-10 pm) coated with a
wax has a lifetime of 54,000 oscillations on the LFW-1 and 16.5 set on the SRV. The
dry MoS, microsize powder itself lasts only 11,000 oscillations on the LFW-1 or
11 set on the SRV. The amplitude is 900 pm. Under the same test conditions a PTFE
film has a wear life of 6000 oscillations on the LFW-1 and 10 set on the SRV, the
amplitude being only 400 pm.

DISCUSSION

Comparing Tables IV-VII it can be stated that these four testing machines are
suitable to preselect lubricants for oscillating machine elements ; the final evaluation,
however, can only be done by results from practice.
It is essential in all lubricant testing with testing machines that all relevant

Wear, 17 (1971) 407419

418 J. G~NSHEIMER. G. FRIEDRI~H

TABLE VII
EVALUATION OFDRY SOLID LUBRICANT FILMS IN THE SRV AND LFW-1 TESTING MACHINES
~ _
Test conditions SRV LFW-1
oscillating

Frequency 50 Hz 1.5 Hz
Amplitude 90”
Load 45 kg 90 kg
Testing time
Test specimen composition Both specimens roller bearing Steel 4620AISI
steel (SAE) 01
Sandblasted,
Ai,O, 125 mesh
Surface roughness Ra = 0.0550.1 pm Ra =0.2 pm
(Ra, DIN 4763)
Humidity, rel. 40-609:, 4@600/,
Coefficient of friction - 0.08

Lubricant comp~sitiffn Test criteria

Amplitude at
beginningof (no.of
test(ptm) nsciilations)

Bonded coating A MoS,(2-10 pm) 1000 31.5 124000

inorganic binder
Powder A MoS,(2-10 pm) 1000 16.5 54000
wax coated
Powder B MoS,(2-10 pm) 900 11 11000
Bonded coating B PTFE 400 10 6000

factors are carefully controlled. The most difficult factors to keep constant and which
dominantly effect the results are surface geometry and lubricant application. This is
especially true with greases, pastes, bonded coatings, and solid lubricant powders.
Tests have to be repeated a sufficient number of times to obtain statistical data.
The present-day trend in industry to lower manufacturing costs and at the
same time design machine elements which transfer more and more power requires
lubricants of ever increasing quality. The development of these lubricants is im-
possible without suitable testing machines and, the testing department of a lubricant
manufacturer is a measure of ability, to develop lubricants.

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Wear, 17 (1971) 407-419