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Haidou Wang Binshi Xu Jiajun Liu Micro and Nano Sulfide Solid Lubrication With 367 figures

Authors Haidou Wang National Key Laboratory for Remanufacturing Academy of Armored Forces Engineering Beijing, 100072, China Email: wanghaidou@tsinghua.org.cn Binshi Xu National Key Laboratory for Remanufacturing Academy of Armored Forces Engineering Beijing, 100072, China Email: xubinshi@vip.sina.com Jiajun Liu Department of Mechanical Engineering Tsinghua University Beijing, 100084, China Email: jiajun7458@yahoo.com.cn ISBN 978-7-03-031785-8 Science Press Beijing ISBN 978-3-642-23101-8 Springer Heidelberg Dordrecht London New York Science Press Beijing and Springer-Verlag Berlin Heidelberg 2012 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Not for sale outside the Mainland of China (Not for sale in Hong Kong SAR, Macau SAR, and Taiwan, and all countries, except the Mainland of China)

Haidou Wang Binshi Xu Jiajun Liu Micro and Nano Sulfide Solid Lubrication

Haidou Wang Binshi Xu Jiajun Liu Micro and Nano Sulfide Solid Lubrication With 367 figures

Authors Haidou Wang National Key Laboratory for Remanufacturing Academy of Armored Forces Engineering Beijing, 100072, China Email: wanghaidou@tsinghua.org.cn Binshi Xu National Key Laboratory for Remanufacturing Academy of Armored Forces Engineering Beijing, 100072, China Email: xubinshi@vip.sina.com Jiajun Liu Department of Mechanical Engineering Tsinghua University Beijing, 100084, China Email: jiajun7458@yahoo.com.cn ISBN 978-7-03-031785-8 Science Press Beijing ISBN 978-3-642-23101-8 ISBN 978-3-642-23102-5 Springer Heidelberg Dordrecht London New York Library of Congress Control Number 2011934496 Science Press Beijing and Springer-Verlag Berlin Heidelberg 2012 This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilm or in any other way, and storage in data banks. Duplication of this publication or parts thereof is permitted only under the provisions of the German Copyright Law of September 9, 1965, in its current version, and permission for use must always be obtained from Springer. Violations are liable to prosecution under the German Copyright Law. The use of general descriptive names, registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. Printed on acid-free paper Springer is part of Springer Science+Business Media (www.springer.com) (eboo k)

Preface In order to cope with the fast development of modern industries, the lubrication of machinery equipment has attracted extensive attention. Although the liquid lubrication is widely used, more and more machine parts are working in the increasingly severe conditions, like high temperature, high load, ultralow temperatures, ultrahigh vacuums, strong radiation, etc. For these working conditions, the commonly used lubricating oils and greases are hardly applicable, so that the solid lubrication is necessary as the supplement for liquid lubrication. The solid lubrication technique was first applied to the aerospace and military industries, after that, it was gradually propagated to the high-tech and newly developed departments of industry. Its development enlarged the application fields of the traditional lubricating oils and greases, counteracted their shortcomings, and the most important result is the emergence of an increasingly large amount of new lubricating techniques using solid lubricants, which are either new materials, or new techniques, exhibiting more important meanings. The practice has proven that the proper adoption of advanced lubrication materials and techniques can effectively prolong the service life of machinery working under the harsh conditions. Furthermore, saving energy and raw materials is the general and urgent requirement today. The rational application for lubricating materials and techniques are even more important economically and socially. This book aims to introduce the advanced solid lubrication techniques of sulfur system to a broad range of readers. It presents the recent research successes of the authors. Based on this, the authors, depending on their profound theoretical basis and experiences in the interdisciplinary field covering tribology, materials science, surface engineering, chemistry, physics and so on, explained the solid lubrication of materials and techniques of sulfur system comprehensively and systematically. They involve microstructures, properties, preparation methods, applications and mechanisms of the solid lubrication materials. Hope this book can be useful to those readers who are interested in the research and application for solid lubrication. The main contents of this book are selected from the authors basic research work in the recent twenty years. However, the solid lubrication is a new area of tribology and lubricating materials; a special and interdisciplinary subject, most phenomena and mechanisms are still in their early stages. What we have discussed in this book may be incomplete or not one hundred percent correct, for this reason, we welcome different opinions or comments from readers. The authors would like to thank Dr. Lina Zhu and Dr. Jiajie Kang for their supports. This book wouldn t be finished without their help. Finally, we are grateful to the National Natural Science Foundation of China (50575225), Beijing Science Foundation (3072011) and Equipment Pre-investigation Foundation (9140A27030107OC85) for their supports towards our research works. Haidou Wang Binshi Xu Jiajun Liu July 2011

Contents Chapter 1 Solid Lubrication Materials...1 1.1 Overview of Solid Lubrication...1 1.1.1 Introduction...1 1.1.2 Adhesive Wear and Scuffing of Metals and Methods of Prevention...2 1.1.3 Solid Lubrication...5 1.2 Soft Metal...9 1.2.1 Crystal Structure...9 1.2.2 Physical and Chemical Properties...9 1.2.3 Lubrication Mechanism...11 1.3 Metal Compounds...11 1.3.1 FeS...11 1.3.2 MoS 2...21 1.3.3 WS 2...36 1.3.4 ZnS...40 1.4 Inorganic Solid Lubricant...46 1.4.1 Graphite...46 1.4.2 BN...48 1.5 Organic Solid Lubricant...51 1.5.1 Polytetrafluoroethylene...53 1.5.2 Polythene...55 1.5.3 Nylon...56 1.5.4 Polyformaldehyde...56 1.5.5 Phenol Formaldehyde Resin...57 1.5.6 Epoxide Resin...58 1.6 Conclusion...58 References...59 Chapter 2 Solid Lubrication FeS Film Prepared by Ion Sulfuration...61 2.1 The Microstructure of Solid FeS...61 2.1.1 Surface Morphologies of Solid FeS...61 2.1.2 Phase Structures of Solid FeS...62 2.1.3 TEM Morphologies of Solid FeS...63 2.1.4 Analysis of Electron Diffraction...63 2.2 The Formation of Iron Sulfuration Layer...64

viii Contents 2.2.1 Experimental Methods...64 2.2.2 Surface Morphologies of Sulfuration Layers...64 2.2.3 Composition on the Sulfurized Steel Surface...66 2.2.4 Phase Structure of Sulfide Layer at Different Sulfurizing Time...67 2.2.5 Formation Mechanism of Sulfurized Layer...68 2.3 Characterization of Ion Sulfurized Layer...69 2.3.1 Characterization of Sulfurized Layer on 1045 and 52100 Steels...69 2.3.2 Characterization of Sulfurized Layer on Four Kinds of Steels...76 2.4 Tribological Properties of Sulfurized Layers...78 2.4.1 Tribological Properties of Sulfurized Layers on 1045 and 52100 Steels...78 2.4.2 Tribological Properties of Sulfide Layer on Four Kinds of Steel...98 2.5 Influencing Factors of the Microstructures and Tribological Properties on Sulfurized Layers...105 2.5.1 Effect of the Substrate State on the Sulfide Layer on 1045 Steel...105 2.5.2 Effect of Environment Temperature on the Sulfurized Layer on 52100 Steel...109 2.5.3 Effect of Wear Conditions on the Tribological Behaviors of Sulfurized Layer on 52100 Steel...112 References...113 Chapter 3 FeS Solid Lubrication Film Prepared by a Two-step Method...115 3.1 Radio-frequency (RF) Sputtering + Sulfurizing Combined Treatment...115 3.1.1 RF Sputtering Technology...115 3.1.2 Process of Preparation...117 3.1.3 Microstructures...117 3.1.4 Tribological Properties...119 3.2 Shot-peening + Ion Sulfuration Combined Treatment...121 3.2.1 Preparation...121 3.2.2 Characterization...122 3.2.3 Tribological Properties of Sulfide Layer...124 3.3 Nitriding + Sulfurizing Combined Treatment...127 3.3.1 1045 Steel Nitriding + Sulfurizing Combined Treatment...128 3.3.2 Gray Cast-iron Nitriding + Sulfurizing Combined Treatment...135 3.4 Nitrocarburizing + Sulfurizing Combined Treatment...138 3.5 Thermal Spraying 3Cr13 Steel Coating + Sulfurizing Combined Treatment...140 3.5.1 Arc Spraying Technology...140 3.5.2 High-velocity Arc Spraying...143 3.5.3 Preparation...143

Contents ix 3.5.4 Microstructures...144 3.5.5 Tribological Properties...146 3.6 Thermal Spraying FeCrBSi + Sulfurizing Combined Treatment...148 3.6.1 Preparation...149 3.6.2 Microstructures...149 3.6.3 Tribological Properties...151 3.7 MIG (metal inert-gas) Welding + Sulfurizing Combined Treatment...160 3.7.1 MIG Welding Technology...160 3.7.2 Preparation...160 3.7.3 Structures...161 3.7.4 Tribological Properties...162 3.8 Mechanism of FeS Film Prepared by Different Methods...165 References...168 Chapter 4 FeS Solid Lubrication Layer Prepared by Other Methods...169 4.1 High-velocity Flame Sprayed FeS Coating...169 4.1.1 High-velocity Flame Spraying Technology...169 4.1.2 Preparation...175 4.1.3 Characterization...175 4.1.4 Tribological Properties of FeS Coating...178 4.1.5 Lubrication Mechanism of Sprayed FeS Coating...183 4.2 Plasma Sprayed FeS and FeS 2 Coatings...183 4.2.1 Plasma Spraying Technique...183 4.2.2 Preparation of FeS (FeS 2) Coating...186 4.2.3 Characterization of FeS (FeS 2) Coating...187 4.2.4 Tribological Properties of FeS (FeS 2) Coating...188 4.3 Plasma Sprayed Nano-FeS and FeS-SiC Composite Coating... 192 4.3.1 Plasma Sprayed Nano-FeS Coating...193 4.3.2 Sprayed FeS-SiC Composite Coating...193 4.4 Comparison of the Tribological Properties of Ion Sulfurized Layer and Plasma Sprayed FeS Coating...194 4.4.1 Experimental Method...194 4.4.2 Microstructure and Tribological Properties...194 4.5 Sol-gel FeS Coating...196 4.5.1 Preparation...196 4.5.2 Characterization...197 4.5.3 Tribological Properties...199 4.6 FeS Film Prepared by S-ion Implantation...203 4.6.1 Ion Implantation Technology...203

x Contents 4.6.2 Tribological Properties of Sulfur-implanted Steel...205 References...205 Chapter 5 Micron-nano MoS 2 Solid Lubrication Film...207 5.1 MoS 2 Film...207 5.1.1 MoS 2 Sputtering Film...207 5.1.2 MoS 2 Film Prepared by Two-step Method...209 5.1.3 Thermal Spraying MoS 2 Film...226 5.1.4 Bonded MoS 2 Film...227 5.1.5 Inorganic Fullerene-like Nano MoS 2 Film...234 5.2 MoS 2 /metal Co-deposition...235 5.2.1 MoS 2/Ni Composite Film...236 5.2.2 MoS 2/Ti Composite Film...248 5.2.3 MoS 2/Au Co-sputtered Film...250 5.3 MoS 2 /Metal Compound Composite Film...251 5.3.1 MoS 2/TiN Composite Film...251 5.3.2 MoS 2/Pb 2O 3 Composite Film...255 5.3.3 MoS 2/LaF 3 Composite Film...255 5.3.4 MoS 2/FeS Multilayer Film...256 5.4 MoS 2 /graphite Sputtered Coating...261 References...263 Chapter 6 Micron-nano WS 2 Solid Lubrication Film...265 6.1 WS 2 Film...265 6.1.1 Characterizations of the Synthetic WS 2 Film...266 6.1.2 Tribological Properties of the Synthetic WS 2 Film...267 6.2 WS 2 /Ag Composite Film...273 6.2.1 Structures of WS 2/Ag Composite Film...273 6.2.2 Tribological Properties of the WS 2/Ag Composite Film...275 6.3 WS 2 /MoS 2 Multilayer Film...279 6.3.1 WS 2/MoS 2 Co-sputtered Film...279 6.3.2 WS 2/MoS 2 Multilayer Film Prepared by Combined Treatment...281 6.4 WS 2 /CaF 2 Composite Coating...287 6.5 Ni-P-(IF-WS 2 ) Composite Film...288 References...290 Chapter 7 Micron-nano ZnS Solid Lubrication Film...291 7.1 ZnS Film Prepared by High Velocity Arc Spraying + Sulfurizing Treatment...291 7.1.1 Preparation...291 7.1.2 Characterizations...291

Contents xi 7.1.3 Tribological Properties...293 7.1.4 Lubrication Mechanisms of the Zn/ZnS Composite Layer...295 7.2 ZnS Film Prepared by Nano-brush Plating + Sulfurizing Treatment...295 7.2.1 Preparation...296 7.2.2 Morphologies...296 7.2.3 Friction Coefficient...297 7.2.4 Worn Morphologies...298 7.2.5 Energy Spectrum Analysis...299 7.3 Conclusion...303 Index...305