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to establish and maintain surface integrity (σi). The design and manufacture of the ingredients play a
significant role in performance. Surface integrity performance attributes are not predictable, they require experimentation. Performance outcomes cover a wide range represented by anti-wear (AW), extreme pressure (EP), and run-in polishing (RIP). Finally, interface design requires strategic linkage between tribology performance attributes and the functional requirements of the mechanical component and its duty cycle. For effective solutions, tribology interface engineering design is a required discipline. New horizons in aerospace tribology are based on Tribology-by-Design (T/D).
Tribology-by-Design (T/D) Tribology-by-Design (T/D) provides solutions to targeted component interfaces through the application of six items: (1) theory, (2) test/analysis tools, (3) methodology, (4) process, (5) strategy, and (6) solution outcome. The first three items are illustrated with a T/D roadmap.
T/D addresses the functional requirements of a targeted component contact interface. The T/D theory from first principles utilises engineering parameters representing the motion, stress, and temperature (MST). These input parameters activate the contact interface tribology materials, manufactured surfaces, mechanisms, and their manifestations (Tm
) during operation through the
interface friction (μ). The theory reduces all contact interfaces interactions to MST-μ-Tm.
Specialised test and analysis tools are used for surface integrity analysis. Component analysis codes are used to extract the required MST parameters. Simulation testing is conducted with special single contact high speed test machines. A single contact model (SCM) is used to conduct all the interface hi calculations, including analysis on an asperity scale from 3D topographical input files. The T/D tools provide a component analysis digital twin, an interface test simulation twin, and an interface digital twin.
The T/D methodology extracts the targeted MST-μ-Tm from the targeted component (TRL 8) and addresses the tribology interface design at a more workable TRL 3 and TRL 4 level. TRL 3 testing and analysis are for tribology performance information. TRL 4 testing and analysis are for component interface simulation and performance design and validation. The theory,
20 LUBE MAGAZINE NO.172 DECEMBER 2022
Figure 4: Tribology-by-Design (T/D) interface engineering is an essential part of the technology supply chain. 9 TRL maturity stages can be achieved through 6 T/D steps to fulfill functional requirements implemented through 6 technology supply chain tiers, including T/D interface engineering: (966).
New horizons in aerospace tribology have T/D engineering as an enabling contributor to the technology supply chain. T/D is implemented through 966. Nine TRL technology maturity levels, six T/D actions, and engagement of six tiers of the technology supply chain.
Acknowledgements: U.S. Air Force (AFRL) U.S. Navy (NAVAIR)
U.S. Army (ARL, DEVCOM AvMC)
www.wedeven.com
test/analysis tools, and methodology enable rapid response, innovative, and timely solutions.
Solutions are achieved through a process that first addresses hydrodynamic (hi) mechanisms. With current traction models all interface film thickness, traction, thermal, and stress analysis for design can be calculated. The process then moves to T/D surface integrity (σi) interface design using information gathered from TRL 3 testing and modeling.
The next step is developing a strategy to meet the functional requirements of the targeted component. This is accomplished through fulfillment of MST-μ-Tm requirements for performance, as well as cost effective manufacturing and service operation.
Implementation of T/D for solution outcome requires the engagement and education of the entire technology supply chain. The supply chain consists of six tiers involving R&D, material suppliers, tribology interface engineering, component suppliers, OEMs, users (or operators).
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