Superlow Friction of a-C:H Coatings in Vacuum: Passivation Regimes and Structural Characterization of the Sliding Interfaces

A combination of atomistic simulations and vacuum tribometry allows atomic-scale insights into the chemical structure of superlubricious hydrogenated diamond-like carbon (a-C:H) interfaces in vacuum. Quantum molecular dynamics shearing simulations provide a structure-property map of the friction regimes that characterize the dry sliding of a-C:H. Shear stresses and structural properties at the sliding interfaces are crucially determined by the hydrogen content CH in the shear zone of the a-C:H coating. Extremely small CH (below 3 at.%) cause cold welding, mechanical mixing and high friction. At intermediate CH (ranging approximately from 3 to 20 at.%), cold welding in combination with mechanical mixing remains the dominant sliding mode, but some a-C:H samples undergo aromatization, resulting in a superlubricious sliding interface. A further increase in CH (above 20 at.%) prevents cold welding completely and changes the superlubricity mechanism from aromatic to hydrogen passivation. The hydrogen-passivated surfaces are composed of short hydrocarbon chains hinting at a tribo-induced oligomerization reaction. In the absence of cold welding, friction strongly correlates with nanoscale roughness, measured by the overlap of colliding protrusions at the sliding interface. Finally, the atomistic friction map is related to reciprocating friction experiments in ultrahigh vacuum. Accompanying X-ray photoelectron and Auger electron spectroscopy (XPS, XAES) analyses elucidate structural changes during vacuum sliding of a hydrogen-rich a-C:H with 36 at.% hydrogen. Initially, the a-C:H is covered by a nanometer-thick hydrogen-depleted surface layer. After a short running-in phase that results in hydrogen accumulation, superlubricity is established. XPS and XAES indicate a non-aromatic 1–2-nm-thick surface layer with polyethylene-like composition in agreement with our simulations.

Cold Welding in Hold Down Points of Space Mechanisms Due to Fretting When Omitting Grease

Cold welding refers to an effect related to space (vacuum). The heavy vibrations during a launch subject interfaces (hold down points) to oscillating motions which may lead to formation of a kind of “friction weld”. If so, these mechanisms may get stuck, and deployment will be hindered. This may endanger the functionality of the mission (instruments) or even the whole spacecraft (if solar panels do not open). Several studies have been done to characterize material combinations (including coatings) for their ability to cold welding in space. Meanwhile, also during launch grease free contacts are demanded. If grease hat to be omitted, the risk of cold welding under fretting was found to increase (when testing in high vacuum). To rate this risk under launch conditions, the test method was recently extended for testing under launch conditions. The new tests procedure consists of fretting applied in the sequence in air, low vacuum and high vacuum. The paper shall present first results gained with this new method of testing in launch conditions and compare them to previous studies done in vacuum. Following the need of space industry on mechanisms for launch and in-orbit life, a first set of combinations of materials and coatings were selected for this new test sequence where fretting is now applied in a sequence of air, low vacuum and high vacuum. Under this sequence, the measured levels of adhesion and it’s evolvement was found to differ strongly from tests done formerly. The paper outlines these first results and compares them to existing data.

Cold Welding Based Space Debris Removal System

Space Debris is a major problem posing a great threat to all the future space travels as well as to all the satellites which are orbiting around the earth. According to a definition by the Inter-Agency Debris Coordination Committee (IADC) “space debris are all man-made objects including fragments and elements thereof, in Earth orbit or re-entering the atmosphere, that are non-functional” [1]. According to J. C. Liou, even if we stop all the space launches the amount of space debris will remain constant up to 50 years but will increase later due to collisions among them [3], [4]. Till December 16, 2019 a total of 20047 objects are on orbit out of which 5370 objects are payloads and 14677 are debris, this means about 73% of the objects in orbit constitutes debris. [2] The rate at which the debris is generated is much greater than the rate at which this debris deaccelerates, leaves the earth orbit and re-enters the earth atmosphere. We can protect the future space missions from huge debris particles that are traceable but the small debris elements pose a major threat. In this paper we propose a technique to remove the small debris particles from Lower earth orbits based on cold welding. Cold welding is the process in which two similar metals stick to each other when there is a metal to metal contact in space. This happens because on the ground these metals have layers of oxides thus, two pure metals never come in contact but in space, due to wear and tear, this layer of oxides get removed irreversibly and as a result, pure metals come in contact and the adhesive forces cause the metals to join. The debris is orbiting around the earth at a speed of 17500 mph [10]. For our system we use a composite material made up of a combination of elements that usually orbit the earth. Since, in relative frames they are stationary by increasing the velocity with controlled amount we can control the impact during contact. We will propel this composite material with the same speed around the earth as the debris, so that in their relative frames it appears stationary. By bringing the debris particles into contact with the composite material, cold welding will take place between them and then, we will send the system to international space station where the captured debris particles are removed from the composite material. By repeating this process, we can remove most of the small debris particles of size less than 10cm which are orbiting around the earth in lower earth orbit.

Effects of Stud Galling on Bolted Flange Joint Assembly Performance

This study will focus on the galling of studs and what impact that has on the overall performance of a Bolted Flange Joint Assembly. Galling or “cold welding” occurs more so with softer metals. While tightening the nut on to the stud the contact metal will “pull” away from itself and the two surfaces will essentially become one. Once this happens the nut cannot be tightened or loosened and often cutting the stud is the only form of removal. We’ll be studying how this affects the performance (tightness) of a bolted flange joint assembly. Does the assembly loosen over time or does it remain at the proper tightness? Data will be captured using load cells to accurately represent the amount of force being generated by test studs. There will be a standard test ran with no galling. All other tests with galled studs will be measured and compared against the standard test. One test with only one stud galled, the next with two studs galled, the next with three studs galled, and so on. It may be expected to see some load loss on the load cells with the galled studs. The integrity of the studs, once galled, becomes less than ideal.