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A novel method for in situ profile measurements on rolling contact test specimens has been demonstrated. A chromatic confocal probe was integrated into a twin-disc machine and used for disc profile measurements during periodically interrupted wear tests. The arrangement allowed detailed studies on the progress of the wear during a test without the removal of discs from the tribometer. Data from the interrupted tests was compared with the results of continuous tests. Both types of tests were run with two grades of cast iron dicsc in lubricated contact with steel. The results of this new method were in good agreement with those of a conventional diamond stylus probe method applied before and after the tests. [ABSTRACT FROM AUTHOR]

Abstract: In this paper, we report the global fuel energy consumption in heavy-duty road vehicles due to friction in engines, transmissions, tires, auxiliary equipment, and brakes. Four categories of vehicle, representing an average of the global fleet of heavy vehicles, were studied: single-unit trucks, truck and trailer combinations, city buses, and coaches. Friction losses in tribocontacts were estimated by drawing upon the literature on prevailing contact mechanics and lubrication mechanisms. Coefficients of friction in the tribocontacts were estimated based on available information in the literature for four cases: (1) the average vehicle in use today, (2) a vehicle with today׳s best commercial tribological technology, (3) a vehicle with today׳s most advanced technology based upon recent research and development, and (4) a vehicle with the best futuristic technology forecasted in the next 12 years. The following conclusions were reached: [•] In heavy duty vehicles, 33% of the fuel energy is used to overcome friction in the engine, transmission, tires, auxiliary equipment, and brakes. The parasitic frictional losses, with braking friction excluded, are 26% of the fuel energy. In total, 34% of the fuel energy is used to move the vehicle. [•] Worldwide, 180,000 million liters of fuel was used in 2012 to overcome friction in heavy duty vehicles. This equals 6.5millionTJ/a; hence, reduction in frictional losses can provide significant benefits in fuel economy. A reduction in friction results in a 2.5 times improvement in fuel economy, as exhaust and cooling losses are reduced as well. [•] Globally a single-unit truck uses on average 1500l of diesel fuel per year to overcome friction losses; a truck and trailer combination, 12,500l; a city bus, 12,700l; and a coach, 7100l. [•] By taking advantage of new technology for friction reduction in heavy duty vehicles, friction losses could be reduced by 14% in the short term (4 to 8 years) and by 37% in the long term (8 to 12 years). In the short term, this would annually equal worldwide savings of 105,000 million euros, 75,000 million liters of diesel fuel, and a CO2 emission reduction of 200 million tones. In the long term, the annual benefit would be 280,000 million euros, 200,000 million liters of fuel, and a CO2 emission reduction of 530 million tonnes. [•] Hybridization and electrification are expected to penetrate only certain niches of the heavy-duty vehicle sector. In the case of city buses and delivery trucks, hybridization can cut fuel consumption by 25% to 30%, but there is little to gain in the case of coaches and long-haul trucks. Downsizing the internal combustion engine and using recuperative braking energy can also reduce friction losses. [•] Electrification is best suited for city buses and delivery trucks. The energy used to overcome friction in electric vehicles is estimated to be less than half of that of conventional diesel vehicles. Potential new remedies to reduce friction in heavy duty vehicles include the use of advanced low-friction coatings and surface texturing technology on sliding, rolling, and reciprocating engine and transmission components, new low-viscosity and low-shear lubricants and additives, and new tire designs that reduce rolling friction. [Copyright &y& Elsevier]

Abstract: This study presents calculations on the global fuel energy consumption used to overcome friction in passenger cars in terms of friction in the engine, transmission, tires, and brakes. Friction in tribocontacts was estimated according to prevailing contact mechanisms such as elastohydrodynamic, hydrodynamic, mixed, and boundary lubrication. Coefficients of friction in the tribocontacts were estimated based on available information in the literature on the average passenger car in use today, a car with today’s advanced commercial tribological technology, a car with today’s best advanced technology based upon recent research and development, and a car with the best technology forecasted in the next 10 years. The following conclusions were reached: [•] In passenger cars, one-third of the fuel energy is used to overcome friction in the engine, transmission, tires, and brakes. The direct frictional losses, with braking friction excluded, are 28% of the fuel energy. In total, 21.5% of the fuel energy is used to move the car. [•] Worldwide, 208,000 million liters of fuel (gasoline and diesel) was used in 2009 to overcome friction in passenger cars. This equals 360 million tonne oil equivalent per year (Mtoe/a) or 7.3millionTJ/a. Reductions in frictional losses will lead to a threefold improvement in fuel economy as it will reduce both the exhaust and cooling losses also at the same ratio. [•] Globally, one passenger car uses on average of 340l of fuel per year to overcome friction, which would cost 510 euros according to the average European gas price in 2011 and corresponds to an average driving distance of 13,000km/a. [•] By taking advantage of new technology for friction reduction in passenger cars, friction losses could be reduced by 18% in the short term (5–10 years) and by 61% in the long term (15–25 years). This would equal worldwide economic savings of 174,000 million euros and 576,000 million euros, respectively; fuel savings of 117,000 million and 385,000 million liters, respectively; and CO2 emission reduction of 290 million and 960 million tonnes, respectively. [•] The friction-related energy losses in an electric car are estimated to be only about half those of an internal combustion passenger car. Potential actions to reduce friction in passenger cars include the use of advanced coatings and surface texturing technology on engine and transmission components, new low-viscosity and low-shear lubricants and additives, and tire designs that reduce rolling friction. [Copyright &y& Elsevier]

Abstract: It has been demonstrated that tetrahedral amorphous carbon (ta-C) films provide excellent wear and friction properties in dry sliding. Recently the applications of ta-C coatings in lubricated conditions have become more important. The use of carbon coatings aims at reducing the wear and coefficient of friction under minimum lubrication and without hazardous lubricant additives. For optimum tribological performance, a modification of the ta-C coated surfaces is required. The present paper describes an innovative method of coated surface texturing, by which nanometer and micrometer size pores are processed by various methods. Particle masking was used for processing micrometer size pores and for controlling the coating growth conditions in order to produce nanometer size pores in the ta-C surface. The masking by particles yielded a pore geometry which varied from complex shaped channels to small individual pores. The texturing was performed by distributing metallic powder particles on the surface or by direct chemical deposition of metal particles on the substrate in prior to pulsed vacuum arc deposition. The tribological characterization was carried out by applying reciprocating friction tests with controlled lubricant replenishment, in order to simulate metal forming processes. The friction reducing effect, which was observed in the tribological tests, indicated a microlubrication effect of the textured coating surfaces. [Copyright &y& Elsevier]