Inaugural lecture for Tomasz Liskiewicz, Professor of Tribology and Surface Engineering, Manchester Metropolitan University, Faculty of Science and Engineering

1. Good and evil of tribological
engineering surfaces
Tomasz Liskiewicz
Professor of Tribology and Surface Engineering

2. …
God made the bulk,
surfaces were invented by the devil
Wolfgang Pauli

3. FRETTING
SURFACES &
TRIBOLOGY
SURFACE
ENGINEERING
FUTURE
OUTLOOK

4. SURFACES and TRIBOLOGY

5. Surfaces
• Absorbing
• Reflecting
• Corroding
• Supporting
• Insulating
• Conducting
• …
Contamination
Adsorbed
Oxide layer
Work harden
Metal surface

6. Surface interactions

7. Interacting surfaces
A.I. Vakis et al., Modeling and simulation in tribology across scales: An overview, Tribology International, Volume 125, 2018, Pages 169-199.

8. Tribology
• Tribology: the science and engineering of
interacting surfaces in relative motion
• It includes the study and application of the
principles of friction, lubrication and wear
• Multidisciplinary subject involving engineers,
physicists, chemists, material scientists
• The most important subject no one has heard of*
*Quote by Professor John Tichy of Rensselaer Polytechnic Institute, New York.

9. Early applications of friction
Rolling objects takes much less energy
than sliding them.
Heat is generated by rubbing two dry
pieces of wood together.

10. Early applications of friction
“History of Tribology”, Duncan Dowson, 2nd Edition, 1998, Professional Engineering Publishing Ltd.

11. Early applications of friction
Source: Daily Mail, Revealed: How 15th century workers used ICY
roads to haul 100-tonne stones to build China's Forbidden City

12. First systematic study of friction
See: Liskiewicz T. Leonardo da Vinci’s early work on friction founded the modern science of tribology, The Conversation

13. “Tribology”
• How much friction and
wear cost the UK
economy?
• 1966 Jost Report
• Cost of friction, wear and
corrosion to the UK
economy 1.36% of GDP
• Word derived from the
Greek term tribos
meaning rubbing
Jost, Peter (1966), Lubrication (Tribology) - A report on the present position and industry's needs, Department of Education
and Science, H. M. Stationery Office, London, UK.

14. 50 years after Jost Report
Holmberg, K. & Erdemir, A. Influence of tribology on global energy consumption, costs and emissions, Friction (2017) 5: 263.

15. My Tribology research
• MSc Thesis: Single and multi-layer carbide coatings on high speed stainless steel
• PHD Thesis: Hard coatings durability under variable fretting wear conditions
• Postdoc: Protective coating design for -Ti-Al alloy components
• Using biomimicry to provide the step change in lubricant additive technology
• Ion release measurements of bio-materials under fretting wear
• Linking nano- and macro-scale friction
• Academic roles: Co-Cr-Mo alloy passive film behaviour under fretting conditions
• Design for failure: remanufacturing & tribology
• Erosion-Corrosion study of coated aluminium alloys for oil & gas applications
• Friction induced evolution of mechanical properties of engineered surfaces
• Engineering the DLC coating/lubricant interface: optimization for effective friction control
• Tribology of novel carbon coatings for automotive components
• Functional coatings for laparoscopic scissor applications
Fretting
DLC coating

16. FRETTING

17. Fretting wear
Turbine engine blade Hip implant taper joint Electrical connector
Fretting wear is surface damage that occurs between two contacting surfaces
experiencing cyclic motion (oscillatory tangential displacement) of small
amplitude.

18. My fretting wear research
• Friction energy capacity approach to predict surface coating endurance under fretting
• Fretting wear of PVD coatings under variable environmental conditions
• Wöhler-like approach to quantify coatings durability under oscillating sliding conditions
• Ion release during fretting at taper joint interface of hip joint prosthesis
• Influence of roughness on sliding and wear in dry fretting
• Impact of variable loading conditions on fretting wear
• Comparison of nano-fretting and nano-scratch tests with nano-indentation
• Novel numerical method for parameterising fretting contacts
• Surface design against fretting corrosion of electrical connectors
• Dynamic changes of mechanical properties induced by fretting
• Fretting wear behaviour of duplex PEO/chameleon coating on Al alloy
Electrical connectors

19. Fretting-corrosion of electrical connectors

20. Automotive connectors
*J. Swingler, J.W. McBride, Proc. 19th Int. Conf. Electric Contact Phenom., Nuremberg, Germany, 1998, pp. 141.
• Increased complexity of automotive
electronics
• In some cases, more than 400 connectors
with 3000 electrical contacts on board
• Up to 60% of electrical problems related to
degradation of electrical contacts by
fretting-corrosion*

21. Repeating exposure of
active metal surface
to the corrosive nature
of the environment
0
0.1
0.2
0.3
0.4
0.5
0 2000 4000 6000
- interface resistance increase
- electrical contact degradation
contactresistance(Ω)
fretting time (s)
relative
displacement
hollow
component
pin
component
contact
pressure
200 μm 50 μm 10 μm
Fretting corrosion
Liskiewicz T, Kubiak K, Jozefczyk D, Surface texturing for improved fretting-corrosion performance of electrical connectors, in J. Swingler
& J.W. McBride (eds), ICEC2016: 28th International Conference on Electric Contacts, Heriot-Watt University, Edinburgh, UK, pp. 63-67

22. Noble vs. non-noble metals
E. Sauger, S. Fouvry, L. Ponsonnet, Ph. Kapsa, J.M. Martin
and L. Vincent, Wear 245 (2000), pp. 39-52
M. Antler, “Contact Fretting of Electronic Connectors,” IEICE
TRANS. ELECTRON., Vols. E82-C, pp. 3-12, 1999.

23. Grit 600/P1200 Grit 320/P400 Grit 120/P120
0 sec.
2000 sec.
4000 sec.
6000 sec.
8000 sec.
Hypothesis
t1
t2
t3
t4
t5
time
smooth

24. Grit 600/P1200 Grit 320/P400 Grit 120/P120
0 sec.
2000 sec.
4000 sec.
6000 sec.
8000 sec.
Hypothesis
t1
t2
t3
t4
t5
smooth rough
time

25. Grit 600/P1200
smooth
Grit 320/P400
rough
Grit 120/P120
very rough
Experimental stup
Plane
specimen
Sphere
Normal load
Displacement
sensor
Pilot study

26. Grit 600/P1200
smooth
Grit 320/P400
rough
Grit 120/P120
very rough
Pilot study

27. Surface texturing
Fretting experiments
Contact resistance measurements
Surface characterisation
cyclic micro
displacements
Methods

28. a) b)
c) d)
e) f)
0
0
3
1
(mm)
(µm)
0
0
3
9
(mm)
(µm)
0
0
3
15
(mm)
(µm)
0
0
3
35
(mm)
(µm)
0
0
5
70
(mm)
(µm)
0
0
5
95
(mm)
(µm)
Test coupons

29. Polished Directional surface texturing
Ra (µm) 0.09 0.75 2.09 5.94 9.51 13.76
Peak height (µm) 0.3 4 12 35 60 115
Peak to peak (mm) n/a n/a 0.44 0.62 0.78 1.00
C101 copper
Test coupons

30. Test methodology
Hemisphere
specimen
Flat
specimen
Volt meter
DC
power supply
Ampere meter
1
4
2
3
V
A
- 7N normal load (P)
- 10μm, 20μm & 30μm peak to peak stroke (δ)
- 30Hz frequency
- Ambient: 22°C, 40-55% RH
- Cycles to failure: 100 mΩ
Experimental stup
Plane
specimen
Sphere
Normal load
Displacement
sensor

31. Failure criterion 100mΩ
Contact resistance
Number of fretting cycles to failure

32. Numberofcyclestofailure
Ra (µm)
0
100000
200000
300000
400000
500000
0 5 10 15
Impact of surface roughness at 30 µm stroke
smooth rough

33. Numberofcyclestofailure
Ra (µm)
0
100000
200000
300000
400000
500000
0 5 10 15
Impact of surface roughness at 20 µm stroke
smooth rough

34. Numberofcyclestofailure
Ra (µm)
0
100000
200000
300000
400000
500000
0 5 10 15
Impact of surface roughness at 10 µm stroke
smooth rough

35. Wear debris
Liskiewicz T, Kubiak K, Mann D, Surface design against third body fretting-corrosion of electrical connectors, Tribology International, under review.

36. SURFACE ENGINEERING

37. 11th Dec 2010

38. Flexicoat 850 coating system
• Physical and Plasma Assisted
Chemical Vapour deposition
• Full-scale industrial system
• Automated coating receipts
• Repeatable coating composition

39. Surface Engineering and Tribology
A.I. Vakis et al., Modeling and simulation in tribology across scales: An overview, Tribology International, Volume 125, 2018, Pages 169-199.

40. What is Surface Engineering?
→ Engineer’s perspective
“… makes possible the design
and manufacture of
engineering components with
combination of bulk and surface
properties unobtainable in a
single monolithic material”
Bell, 1985
Surface Engineering

41. Surface Engineering methods
DLC

42. • DLC is a generic term describing a range of amorphous carbon
• Diamond & graphite the most well-known allotropes of carbon
• different type of bonding between carbon atoms
•
DLC - Diamond-like carbon coatings have a mixture
of sp3 and sp2 bonds
Diamond
• hard
• sp3 hybridized bonds
resulting in strong C-C
bonds
Graphite
• soft and slippery
• sp2 hybridized bonds forming
weak bonding between the
atomic planes
Diamond-like Carbon (DLC) coating

43. Diamond-like Carbon coating
• Nano-mechanical characterisation
• Nano-indentation
• Nano-scratch
• Nano-impact
• Coating applications
• Internal combustion engine lubrication
• High performance motorsport engine
• Flow assurance in oil & gas sector

44. Diamond-like Carbon coating
• Nano-mechanical characterisation
• Nano-indentation
• Nano-scratch
• Nano-impact
• Coating applications
• Internal combustion engine lubrication
• High performance motorsport engine
• Flow assurance in oil & gas sector

45. Nano-mechanical characterisation
Indentation Scratch Impact (sample oscillation)
Reciprocating Impact (pendulum impulse)
High cycle fatigue
Low cycle fatigue
Dynamic hardness
Accelerated (reciprocating)
nano-wear, nano-fretting

46. Nano-indentation
Beake B, Liskiewicz T, Vishnyakov V, Davies M, Development of DLC coating architectures for demanding functional surface applications through
nano- and micro-mechanical testing, Surface and Coatings Technology, 2015, Vol. 284, 334-343.
H (GPa) Er (GPa) hc (nm) H/Er
a-C:H 25.0 ± 1.1 194.7 ± 5.4 227.1 ± 5.9 0.128 ± 0.003
Si:a-C:H 16.3 ± 0.5 143.3 ± 2.9 287.3 ± 4.7 0.114 ± 0.002
a-C:H:W 12.7 ± 1.7 157.1 ± 13.3 331.9 ± 26.5 0.081 ± 0.005

47. Nano-scratch
Beake B, Davies M, Liskiewicz T, Vishnyakov V, Goodes S, Nano-scratch,
nanoindentation and fretting tests of 5–80nm ta-C films on Si(100),
Wear, 2013, Vol. 301, 575-582.
a-C:H:W
Si:a-C:H
a-C:H
Ly = (206 ± 5) mN
Lc1 = (422 ± 4) mN
Ly = (110 ± 10) mN
Lc1 = (445 ± 12) mN
Ly = (68 ± 4) mN
Lc1 > 500 mN

48. Nano-impact
Shi X, Beake B, Liskiewicz T, Chen J, Sun Z, Failure mechanism and protective role of ultrathin ta-C films on Si (100) during cyclic nano-impact,
Surface and Coatings Technology, Vol. 364, 2019, 32-42.

49. Diamond-like Carbon coating
• Nano-mechanical characterisation
• Nano-indentation
• Nano-scratch
• Nano-impact
• Coating applications
• Internal combustion engine lubrication
• High performance motorsport engine
• Flow assurance in oil & gas sector

50. DLC/lubricant interaction in internal combustion engine
Austin L, Liskiewicz T, Kolev I, Zhao H, Neville A, The influence of anti‐wear additive ZDDP on doped and undoped diamond‐like carbon coatings,
Surface and Interface Analysis, 2015, Vol. 47, 755-763.

51. DLC/lubricant interaction in internal combustion engine
5 μm x 5 μm
Fully Formulated Oil
10 μm x 10 μm
5 μm x 5 μm
Base Oil
10 μm x 10 μm
Austin L, Liskiewicz T, Kolev I, Zhao H, Neville A, The influence of anti‐wear additive ZDDP on doped and undoped diamond‐like carbon coatings,
Surface and Interface Analysis, 2015, Vol. 47, 755-763.

52. Textured DLC coating
Koszela W, Pawlus P, Reizer R, Liskiewicz T, The combined effect of surface texturing and DLC coating on the functional properties of internal
combustion engines, Tribology International, Vol. 127, 2018, 470-477.

53. Textured DLC coating
Koszela W, Pawlus P, Reizer R, Liskiewicz T, The combined effect of surface texturing and DLC coating on the functional properties of internal
combustion engines, Tribology International, Vol. 127, 2018, 470-477.
5.8% engine power increase
for DLC coated & textured cylinder

54. DLC coating for protection of flow control devices
Temperature 100°C/212°F
Pressure 1000 psi/6.89 MPa
Gas 5% H2S, 5% CO2, 90% CH4
Water 1% NaCl in distilled water
Hydrocarbon Toluene:Kerosene (1:1 volume)
Duration 28 days
Liskiewicz T, Al-Borno A, DLC Coatings in Oil and Gas Production, Journal of Coating Science and Technology, 2014, Vol. 1, 59-68.

55. DLC coating for protection of flow control devices
Liskiewicz T, Al-Borno A, DLC Coatings in Oil and Gas Production, Journal of Coating Science and Technology, 2014, Vol. 1, 59-68.
VinylEster
(3 coatings)
Phenolic
(6 coatings)
Epoxy
(8 coatings)
Phenol-formaldehydeResin
(14 coatings)
Coating types
included in the comparative study
31
13
2Numberofcoatings
Coatings
in the study
Coatings passed
slow decompression
Coatings passed
rapid decompression
Thin DLC coating (1.43 μm)
showed superior performance
to most thick organic “industry
standard” coatings

56. FUTURE OUTLOOK

57. Ten years from now, AI-enabled
companies will be far more valuable
than the current FAANG and BAT
stocks
Voice of the CEOs at the latest
Fortune Global Tech Forum
(Guangzhou, China)
FAANG: Facebook, Apple, Amazon, Netflix and
Alphabet’s Google
BAT: Baidu, Alibaba and Tencent

58. Moore’s law
Martin E, Moore’s Law is Alive and Well, Medium, https://link.medium.com/HzbiDGB9hX
Transistor count per
microprocessor by year

59. Exponential growth of computational power
Beauty and Joy of Computing, University of California, Berkeley and Education Development Center, https://bjc.edc.org/bjc-r/course/bjc4nyc.html

60. Exponential growth of knowledge
• The more we know, the greater our ability to
learn new things
• The greater our ability to learn the faster we
expand our knowledge base
• Each new scientific discovery becomes a tool
with which novel technologies are invented
• Growth of knowledge fuels growth of
technology
• Technology feeds on itself

61. Exponential growth surprise factor
Yelton S, Why Enterprises Need Communications in the Cloud, https://www.windstreamenterprise.com

62. • Additive Manufacturing
• Big Data & Analytics
• Cybersecurity
• Autonomous robots
• Simulation
• The cloud
• Horizontal & Vertical Integration
• Industrial Internet of Things
• Augmented Reality
The 9 pillars and drivers of Industry 4.0
Source: Boston Consulting Group

63. Industrial Internet of Things and Sensors
Source: www.ncta.com and www.postscapes.com

64. Coating as a sensor
DLC Coating on HTS:
FIB-SEM after 75 impacts at 1 N
Coating electrical resistance
measurement setup

65. Coating resistance measurement

66. DLC coating resistance vs. applied load at 50V
26.23295
21.07926
11.16071
6.944444
5.376344
3.31565
-5
0
5
10
15
20
25
30
35
0 1 2 3 4 5
CONTACTRESISTANCE[m]
LOAD [kg]

67. Industry 4.0 theme at Manchester Metropolitan

68. Summary
• Good rather than evil surfaces & exciting
times for tribology and functional surfaces
• Remaining challenges in niche tribology field
of fretting wear
• Moving from passive coating to connected-
sensing-responsive surface, real time
condition monitoring of machines, better
prediction of wear
• The difficulty of working across barriers is not
to be underestimated. What will distinguish
successful institutions will be cross-
disciplinary approach.
FRETTING
FUTURE
OUTLOOK
SURFACE
ENGINEERING
SURFACES &
TRIBOLOGY

69. Acknowledgments
A Neville, B Wendler, M Bryant, L Yang, D Barton, A Morina, M Priest, D Dowson, N Kapur, H Thompson,
M Wilson, K Kubiak, T Mathia, S Fouvry, C Wang, R Dwyer-Joyce, A Matthews, B Beake, J Colligon,
T Charpentier, T Childs, R Chittenden, S Kosarieh, F Motamen Salehi, P Parsaeian, A Ghanbarzadeh,
S Soltanahmadi, S McMaster, Z Thompson, E McNulty, R Brittain, F Dangnan, NRBN Roseley, AM Algahtni,
L Austin, M Lgried, J Endrino, D Mann, R Whiting, A Oladokun, T Hobeika, F Thirion, D Jozefczyk, H Attia,
I Bargmann, TZ Lwin, V Khetan, T Khan, S Carley, F Mangolini, D Khaemba, A Cavaleiro, J Sayed, C Dyson,
S Brasil, D Freitas, K Dahm, P Dearnley, J Stanford, M Gester, W Cox, T Wilkins, A Barnett, X Shi, J Chen,
S Yamamoto, W Koszela, P Pawlus, A Yerokhin, A Voevodin, X Wei, D Wei, H Zhao, T Comyn, A Tiwari,
V Vishnyakov, M Davies, I Kolev, D Doerwald, R Tietema, A Al-Borno, N Schwarzer, A Harris, S Shrestha,
G Liskiewicz, P Kula, R Pietrasik, R Roshan, P Gaskell, L Chen, G Taylor, M Kalbarczyk, Y Yan, S Achanta, D Drees,
J-P Celis, R Rybiak, H Renondeau, C Paulin, T Pacyniak, D Rylska, A Rylski, L Kaczmarek, W Pawlak, Ph Kapsa,
L Vincent, S Rao, S Dhoke, X Chen, R Kamble, J Cortes, R Hewson, V Fridrici, B Januszewicz, I Gebeshuber