UMT Tribolab

Concept and Applications

Patrick Markus
Bruker – Nano Surfaces Division
[email protected]
Agenda

• What is the UMT-Tribolab

• Applications
• Scratch on polymer coating
• High temp hardness
• Wet clutch testing
• Brakepad material characterization
• Instrumented Indentation

2
UMT-Tribolab
building it up

3
UMT-Tribolab Lower Drive Types
Linear & Reciprocating Drives

Reciprocating Drive Technical Specifications

Max. Stroke 25 mm
Min. Stroke 0.1 mm
Position resolution 1µm
Speed 0.1 to 60 Hz
Max. Load 2,000 N
60 Hz @ 2 mm
Stroke vs Frequency
20 Hz @ 25 mm

4
UMT-Tribolab Lower Drive Types
Rotary & Block-on-Ring Drives

Rotary Drive Technical Specifications

Speed 0.1 to 5,000 rpm
Max. Torque >5 Nm @ 100 rpm, 2.5 Nm @ 5,000 rpm
Max. Load 2,000 N

Block-on-Ring Drive Technical Specifications

Speed 0.1 to 5,000 rpm
Max. Torque >5 Nm @ 100 rpm, 2.5 Nm @ 5,000 rpm
Max. Load 2,000 N

5
 UMT-Tribolab Force Sensors

SPECS\MODEL FVL-G FL-G DFM-0.5-G DFM-1-G DFM-2-G DFH-5-G DFH-10-G DFH-20-G DFH-50-G DFH-100-G DFH-200-G
Low 1mN 5mN 0.05N 0.1N 0.2N 0.5N 1N 2N 5N 10N 20N
High 100mN 500mN 5N 10N 20N 50N 100N 200N 500N 1,000N 2,000N
Resolution 10µN 50µN 0.25mN 0.5mN 1mN 2.5mN 5mN 10mN 25mN 50mN 100mN

FL series DFM series DFH series

Fx

Fz

6
 Wide Range of Advanced Sensors for
Environmental and Test Characterization

• Advanced Sensors are field-

installable, and easy to configure
to add increased test
characterization and accuracy of
the UMT-Tribolab system.

• Advanced Sensors available

include:
• Acoustic Emission
• Electrical Contact Resistance
• Temperature
• Humidity
• Micro-Wear, Deformation

Acoustic Emission Sensor Used to Detect

Coating Delamination

7
UMT-Tribolab Product Selector Guide
Main Unit and Lower Drive Accessories

ROT-HUMID/COOL REC-HUMID/COOL
L-DRIVE

ROT-1000 REC-1000

ROT-400 REC-350

BOR-150

ROT-DRIVE REC-DRIVE
BOR-DRIVE

8
Applications
Examples

9
 Applications

• Scratch testing polymer coating

• High temperature hardness testing

• Wet clutch testing

• Brakepad material characterization

• Instrumented Indentation

10
Scratch testing on polymer coated
roof-tiles

11
TriboLab Setup for Ball-on-Disk Tests
DFH-20 Sensor and Rotary Drive

2D Force Sensor DFH-20

Spring Suspension

Upper Specimen Holder with

Alumina Ceramics Ball  6 mm

Test sample

Sample Fixture Disk

Rotary Drive

TriboLab Setup for Ball-on-Disk Tests

Ball-on-Disk Test Overview
Test Parameters

Rotary Ball-on-Disk
Dry Sliding Friction Test
Ball = Alumina Ceramics  6 mm
Load = 30 N
Test Radius = 10 mm / 5 mm
Frequency = 90 rpm = 1.5 rev/s
Linear Speed = 94 mm/s / 47 mm/s
Duration = 600 s
Revolutions = 900
Sliding Length = 56.5 m / 28.3 m

(or shorter: tests are stopped when metal

substrate is reached)

Acquisition Rate = 100 data points/s

Ball-on-Disk Test – Analysis
Total Wear Depth

Z-stage position - averaged over 1 full rotation of disk

(= 67 data points or 0.67 sec @ speed of 1.5 rev/s)

This is a measure for the total wear (ball + flat).

This signal may also include contributions from:
1) elastic deformation
2) thermal expansion if sample heats up in test

(Note: these are the full 600 s from the test with 30 N load on the sample PUR1-MB)
Ball-on-Disk Test – Analysis
Wear, Friction and Surface morphology

• Rotary Ball-on-Disk test.

• Measure Friction and Wear as function of time.

Wear Depth [mm] Friction Coefficient COF Wear Track on Flat

(Examples on this page are for sample PUR1-MB)

The Samples
Overview

Steel sheets with various coatings

PUR1-B PUR1-MB PES1-B PES1-MB PES2-B PES3-MB

Outer circle: 10mm radius - 30 N load - 1.5 rev/s  94.2 mm/s

Inner circle: 5 mm radius - 30 N load - 1.5 rev/s  47.1 mm/s

Testing time was 600 s for the PUR samples, but shorter for the PES samples.
Tests on PES were stopped after the steel was reached).
Ball-on-Disk Test – Results
Wear Depth
Overview – All samples – All tests

• Samples show a wide variation of durability

• Lower speed is in all cases more destructive
Dotted lines = Test Radius 5 mm = Speed 47 mm/s
Full lines = Test Radius 10 mm = Speed 94 mm/s

PUR1-MB

PES1-MB
PES3-MB

PES1-B
PES2-B

PUR1-B
Ball-on-Disk Test – Results
Wear Depth
Overview – All samples – All tests

Dotted lines = Test Radius 5 mm = Speed 47 mm/s

Full lines = Test Radius 10 mm = Speed 94 mm/s

PUR1-MB

PES1-MB
PES3-MB

PES1-B

PES2-B

PUR1-B
Ball-on-Disk Test – Results

Wear Depth
Some Conclusions

• Both higher speed (r = 10 mm) and lower speed (r = 5 mm) tests result in
the same ranking of coating durability:

1. PUR1-B Only weak signs of decay at t = 600 s.

Will likely last for a few more 100 sec.
2. PUR1-MB Fails in 2 steps – seems to be 2 layers:
Top layer is about 20-25 µm thick
3. PES1-MB most durable PES sample

Durability
– fails quite abrupt after ca 200 s.
4. PES1-B starts to fail after ca 30 s.
5. PES2-B starts to fail after ca 15 s.
6. PES3-MB starts to fail from the first second.
Metal is reached within 20 to 30 s.
High Temperature Hardness
testing

20
Different methods for indentation

1. Mohs’ (Relative scratch: one material against the other, qualitative scale)
2. Brinell (A ball is pressed into surface and remaining diameter measured,
quantitative with MPa unit-scale)

3. Rockwell (minor-load, max-load, minor-load, difference in depth,

qualitative scale)

4. Vickers/Knoop (indentation at given laod and measure indent with

optical microscope, quantitative with Stress (Load/area) unit-scale)

5. Shore (pin indentation on soft material, qualitative scale)

A Viable Method for
High Temperature Hardness:

• Use Rockwell-style method for change in depth

at minor load
• Choose Appropriate Indenter and load
• Small WC ball (3.2 mm diam), 50 kg major load

• Provide descriptive designation

3.2 Ball Diam in mm
• HBB50
Major Load in kg

22
UMT-Tribolab Hot Hardness configuration

1000 N
Force
Sensor

Sample
Thermocouple

1/8” Diam.
Cover Gas WC Ball
Inlet Port

23
 3.2
Results HBB50

1/8” WC ball, 50 kg load, 800°C

1st minor
load
Blue trace is
z-position

Major load

30 sec const. Temp 2nd minor

load

HBB = 100 – ½(129.4) = 35.3

Shows average value of selected

value between cursors
24
 3.2
Results HBB50

PM-A would be a
suitable substitute
for 304 SS at or
below 400°C

PM-B would be
better than 304 SS
up to 700°C, and
equal to Inconel
718 up to 600°C

Inconel 718 is best

choice at 800°C

25
Wet clutch testing

26
27
Hardware requirements for the benchtop
wet-clutch screening test

• The required hardware: the UMT-Tribolab base system, a rotary

drive, a load and torque force sensor and the special accessories
for the wet clutch test

28
Hardware explained

29
Hardware explained (2)

30
31
32
Results: Speed-Slip Step Tests
Different Clutch Materials

33
Results: Speed-Slip Step Tests
Different Clutch Materials

34
35
Example: Speed-Ramp Test

36
Brakepad material characterization

37
Current equipment:
Dynamometer

• Time-consuming to
set it up

• Expensive systems

• Duration of tests are

extremely long before
first results come out
of it

• Long measurement
cue at test labs

May 2, 2011 Bruker Confidential 38

UMT TriboLAB – Brake Material Tester

Aug 1-2, 2017 39

Replicating the Dyno Conditions

5 Key Tribology-elements:
• Materials
• Contact Geometry
• Loading
• Motion
• Environment

6/1/2018 40
1. Materials

•Use same Materials as used in Dyno Test

6/1/2018 41
2. Contact Geometry

Minimum Contact Size due to Non Homogenous Nature of Material

Choose button sample size to be 25x

larger than area shown in this image,
to capture inhomogeneous mixture

0.5 mm

Use three buttons from each

pad to further get “average”
representation of material

<- Finish rotor to 320 grit, as in Dyno testing

6/1/2018 42
 4. Motion - Velocity

Need to replicate car brake pad sliding speed on UMT TL

test pads

Wheel
Diamet
er

UMT
Rotor Effective radius
Radius
Vehicle velocity (km/h)
Wheel rpm = x (103 m/km) x (h/60 min)
π x tire diameter (m/rev)
Sliding Velocity Sliding Velocity
at Brake Rotor = Wheel rpm x π x rotor diameter (m/rev) x (min/60 sec) = at button sample
(m/sec) (m/sec)
sliding velocity at button (m/sec)
UMT rpm = x (60 sec/min)
π x button path diameter (m/rev)
 UMT TriboLABTM
Brake Material Screening

Varying the speed from 2089 to 787 rpm (80-30 km/h) in 5.5
The whole story in one plot.. s, under an applied force of 300N (0.75 MPa contact
pressure). Force and speed are controlled, while torque and
temperatures are monitored. Typically, torque increases while
speed is reduced at constant contact pressure
Deceleration
2500 500 140 140 6

120 120
2000 400

Tz: Torque (N*m)

100 100
V: Speed (rpm)

4
Fz: Force (N)

Trotor (°C)
1500 300

Tpad (°C)
80 80

60 60
1000 200
Fz 2
V 40 40
500 100 Tpad
Trotor 20 20
Tz
0 0 0 0 0
0 2 4 6 8 10 12 14

June 1, 2018 44
Dynamometer vs Tribolab

June 1, 2018 45
 UMT TriboLABTM
Brake Material Screening

CoF 0.6 400 0.6 400

350 350
0.5 0.5
300 300

Rotor Temperature (°C)

Rotor Temperature (°C)

Coefficient of Friction

Coefficient of Friction
0.4 0.4
250 250

0.3 200 0.3 200

150 150
0.2 0.2
100 100
0.1 0.1
50 50

0.0 0 0.0 0
1 2 3 4 5 6 1 2 3 4 5 6
Dynamometer UMT-TL

The data collected during the tests show good correlation between the full-scale
and the benchtop tests, not only from the calculated average coefficient of
friction (CoF), but also in the behavior of the torque that has similar trend and
shape.
June 1, 2018 46
 UMT TriboLABTM
Brake Material Screening

Contact Pressure

0.6 400 0.6 400

350 350
0.5 0.5
300 300

Rotor Temperature (°C)

Rotor Temperature (°C)

Coefficient of Friction

Coefficient of Friction
0.4 0.4
250 250

0.3 200 0.3 200

* * *
150 150
0.2 0.2
100 100
4000 kPa fluid
2000 kPa fluid

3000 kPa fluid

0.1 0.1
50 50

0.0 0 0.0 0

0.39

0.52
0.65
0.78

0.91
1.04

1.17
1.30
0.33

0.66
0.99
1.32
1.65
1.98
2.31

2.64

Contact Pressure [MPa] Contact Pressure [MPa]

Dynamometer UMT-TL

shows step 6.4.2 aimed to measure the sensitivity to applied brake pressure
when testing the system at snubs of 80-40kmh

June 1, 2018 47
 UMT TriboLABTM
Brake Material Screening

CoF Cold Application

0.6 300 0.6 300

0.5 250 0.5 250

Rotor Temperature (°C)

Rotor Temperature (°C)

Coefficient of Friction

Coefficient of Friction
0.4 200 0.4 200

0.3 150 0.3 150

0.2 100 0.2 100

0.1 50 0.1 50

0.0 0 0.0 0
1 2 3 4 5 6 1 2 3 4 5 6
Dynamometer UMT-TL

Good correlation between dyno and UMT-TL results testing materials at

40°C (“Cold Application”, step 6.6), the values of CoF were very close

June 1, 2018 48
 Dynamometer vs Tribolab

Green µ
Rec. 1 (µF1) 0.5 Burnish 1
0.4

0.3
Fade 1 (µF1) Char. 1 (µ0P61)
0.2

0.1

0.0

Cold (µT40) 40-5

Char. 2 (µ0P61) 80-40

Dynamometer Material A
µ120 120-80
UMT Material A

Most of the values are within 10% difference – Good correlation according to
industry experts

June 1, 2018 49
Instrumented Indentation

50
Nano-, micro-, macro-indentation

• The UMT-Tribolab is capable of obtained loading-

unloading curves

• However, the force range and indentation depth

is not as low as with a nano-indenter.

• Full analysis of Hardness and Youngs Modulus is

possible.

51
Example: Indentation in glass

• 10 loading-unloading
curves on glass

• Vickers indenter

• Indentation depth and

loading force indicates
this is ‘micro-indentation’

• Great repeatability

6/1/2018 52
Example: Indentation on glass

6/1/2018 53
Applications/Tech Notes/Webinars

• Various topics available

(more to come):
• Glass Defects
• Hot Hardness & Hot Rolling
• 3-Point Bending
• Stribeck Curve (rotary and
reciprocating)
• Wet clutch testing
• Brakepad testing
• Lubricants testing
• Coatings

• Technical Webinars at [email protected]

Cell: +31 6 5175 9884
Bruker.com/tribology
54
©May
1. Juni2,2018
Copyright Bruker Confidential Information
2011Bruker Corporation. All rights reserved 55
55