O + P »Ölhydraulik und Pneumatik« 46 (2002) Nr.

9 1

Tribological optimisation using laser-structured contact surfaces

Dipl.-Ing. Andreas Hoppermann

Institute for Fluid Power Drives and Controls (IFAS), RWTH Aachen

Dipl.-Ing. Mario Kordt

Fraunhofer Institute for Production Technology (IPT) Aachen

Introduction
Hydraulic systems are being used to an ever-increasing extent in mechanical
engineering installations and the field of application includes both stationary and
mobile plants. Apart from being capable of making large amounts of energy available
quickly and precisely, one of the most important characteristics of a hydraulic system
is its high force density. The demand for higher dynamic performance, energetic
efficiency and long service life is leading to a situation in which hydraulic components
are having to meet more stringent requirements. Hydraulic components are therefore
particularly predestined for innovative tribological optimisation concepts.

The operational reliability and functionality of hydraulic systems must be assured by

the large number of sliding contacts found in hydraulic assemblies, among other
things, and these frequently constitute the areas that are subject to the greatest
loads. Friction between the sliding faces of the mating tribological contact surfaces
exerts a significant influence on this behaviour. Examples in practical and research
applications have shown that the tribological properties can be improved by coating
the mating surfaces and adapting the materials used. Experience has also shown
that the functional micro-geometric design of the contact surface plays an important
role.
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The current idea of an ideal contact surface is based on an even structure produced
by cutting processes with such geometrically undefined cutting operations as
grinding, polishing or lapping, aiming to reduce the surface roughness to a minimum.
More recent research shows, however, that there is further design potential for
optimisation of a tribological system that goes well beyond a perfectly smooth surface
[Be, Kl-1].

In practice, tribological systems that have been designed on the basis of mating such
materials as steel with nonferrous heavy metals - usually bronze alloys - are state of
the art in industrial hydraulic displacement units. Hardened steel is mated with steel
as a typical material combination used in slide valves. During the last few years,
research has been primarily focussed on developing reasonably priced material
combinations, whereby new fields of application have been opened up by coating
technology, as well as the choice of such solid materials as ceramics. PVD
technologies and thermal spraying methods, in particular, have proven their
expedience in hydraulic displacement units [Ne, vB].

The structure of a hydrodynamic load-bearing film can be positively influenced by the

selective introduction of microstructures, offering a means of reducing the frictional
forces and wear rates. Potential applications particularly include those tribological
contacts with higher relative velocities [An]. Micro-structured materials, usually
ceramics with geometrically undefined porosity, are also already being used in
traditional sliding bearing engineering. As a rule, it is not possible to alter the porosity
without modifying the mechanical properties at the same time.

An interdisciplinary team, made up of experts from the Institute of Fluid Power

Transmission and Control (IFAS) and the Fraunhofer Institute for Production
Technology (IPT), is investigating various tribological and production technology
issues and is working on a solution concept for fluid technology applications within
the framework of a research project on "Improved wear and friction performance of
hydraulic components using laser-structured contact surfaces – TriboStruk". The
integration of two research bodies in this project promotes and guarantees a
competent, application-oriented approach to the subject and ensures realisability in
practical industrial concepts.
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The basic principles of tribology

Generally speaking, tribology is concerned with the phenomena referred to as wear
and friction. A tribological system essentially comprises four basic elements: a basic
component and a mating component, each having a contact surface, an inter-
component medium and an ambient medium. The basic component and mating
component are moved relative to one another, but not necessarily all the time.

The tribological system, Fig. 1, reacts to a load collective, that can be derived from
the conditions under which the higher-level function group is operating, whereby the
four basic elements can interact with one another. The reciprocal effects may be of a
chemical, mechanical or general physical nature. While they can be selectively used
to form protective tribological reaction layers, for example, efforts are also being
made to inhibit those reciprocal actions that could lead to detrimental effects as is the
case with abrasion or adhesion phenomena. The micro-geometric structure of the
contact surfaces is one significant influential factor, as this is instrumental in
introducing force into the basic and mating components.

Material
> Facture toughness
FN > Strength
>

Mating component
v Functional surface Lubricant,
> Roughness
> Undulation
ambient medium
Inter-component medium
> Micro/macrostructure > liquid
> > solid
> gaseous

Basic component
Operating conditions
> Contact geometry
> Spec. load
> Temperature
>

Fig. 1: The tribological system

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If the characteristics of a tribological system are to be improved, the wear rates of the
hydraulic tribological contacts must be minimised and the friction losses produced
during relative motion must be reduced, as well as the stiction at the beginning of a
movement. Using the Stribeck curve, which shows the frictional force or coefficient of
friction over the relative velocity Fig. 2, to characterise the frictional behaviour of a
tribological system, optimisation can be determined with respect to two criteria.
Frictional force

Stribeck curve

Mixed friction Fluid friction

Stiction

Curve 1
Minimum
frictional force 1

Curve 2
Minimum
frictional force 2
Transition Transition
point 2 point 1 Velocity

Fig. 2: Effects of frictional optimisation on the Stribeck curve

Firstly, the transition between mixed friction and hydrodynamic friction shifts as the
velocity drops and, secondly, there is a reduction in the general friction level. To
maintain clarity, boundary surface effects that can be attributed to the reaction
products of surface-active additives and occur at very low velocity, are not shown in
the Stribeck curves.

The strategy to be pursued in an effort to reduce friction and wear therefore initially
considers the way in which the fluid is made available by micro-cavities in the
surface. In one respect, the micro-cavities themselves perform the function of a
hydrostatic micro-bearing. When the contact surfaces approach one another, the fluid
in the closed micro-cavities is compressed, thereby producing bearing pressure.
Open cavities, on the other hand, would allow the fluid to flow out of the contact gap,
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allowing the pressure to drop. The capacity of the fluid must also be taken into
consideration, however, as the fluid columns stored in the cavities are more
compressible that the thinner film of fluid spread over the plateau. The build-up of
hydrodynamic bearing films is also assisted in conjunction with convergent micro-
fissions.

p U2=Urel
p

h(x) U2=0
x V12=Vrel x
h(t)
U1=0 U1=0
Wedge effect (vertical) Squeeze effect (vertical)

Fig. 3: Pressure build-up between two moving components

A qualitative representation of the fundamental principles for the build-up of pressure

between two components moving relative to one another described in the Reynolds
equation is shown in Fig. 3. The wedge effect causes pressure to be built up as a
result of the relative movement of an incident contact surface. The squeeze effect
occurs when the parallel contact surfaces are moved towards one another,
compressing the fluid that separates the surfaces.

References
In [Ob], good results are achieved within the framework of research into materials for
variable displacement pumps and motors run on HFA using slide bearings made of
mechanically resistant materials that are intercalated into a restored matrix, offering a
means of preventing inadequate lubrication conditions in the sliding contact. It also
becomes evident that hydrodynamic bearing films can be built up as a result of
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specific surface topographies. However, advantages can only be achieved for mating
materials which are capable of producing a functioning tribological system without
these supportive hydrodynamic measures. Fluid reservoirs must therefore be set up
to provide a reliable supply of fluid to the sliding contact. Furthermore, measures
must also be taken to ensure that the fluid is not carried out of the reservoir by the
relative movement of the mating components. Preference should therefore be given
to closed cavities that are not joined to one another [Be].

Apart from undulating surfaces [Ob], dimple-like indentations also exert a positive
influence on the formation of the pressure profile, with each dimple acting as a micro-
wedge gap bearing [Ze, DP, Kno]. Undulated surfaces of solid bodies always make
initial contact with one another at the faces that project beyond the profile as a whole.
Higher local contact potential occurs at these points though, which can lead to the
material being damaged. There is no interference with the macro-geometry of the
contact surface produced by undulation and surface roughness and this must
therefore be regarded as the main advantage of the dimpled structure. Furthermore,
the load-bearing capability and stability of a lubricant film can be improved by pore-
like indentations in the surface [Ni, Kn].

0.15 Coefficient of friction [-] Mating surfaces:

structured/structured
polished/polished
structured/polished
0.1
Sliding abrasion test (500th cycle):
Material: SiSiC ceramic
0.05 Surface pressure: 1.0 N/mm 2

Oil pan temperature: 50 °C

Oil: VG 68
Type of acceleration curve:
0
Ramp function (60s/30s/60s)
1 2 3 4 5 6
Sliding velocity [m/s]

Fig. 4: Friction performance of laser-structured ceramic sliding rings

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Using ceramic axial face seals as examples, the friction and wear behaviour of laser-
structured surfaces was determined by comparison with surfaces polished in the
conventional manner - Fig. 4 - at the Fraunhofer IPT within the framework of a key
programme backed by the German Research Committee (DFG). The coefficient of
friction for the friction pairing with one laser-structured surface was around 40% lower
than the conventional polished/polished friction pairing and its service life was nearly
twice as long without any increase in leakage. In addition to this, laser-structured
axial face seals demonstrated greater load withstand capability in terms of sliding
velocity, temperature and pressure [Kl-2].

Compared with such alternative manufacturing technologies as ultrasonics or

electrical discharge machining (EDM), laser structuring makes a positive contrast in
[An]. Ceramic sliding rings with dimpled surfaces are the subject of further
investigation. Increasing the number of dimples improves wear behaviour, whereas
hydrodynamic effects improve the tribological system performance. There is no
detectable increase in leakage.

[Be, Ka] examines the tribological properties of ceramic surfaces that have been
structured by means of excimer laser. The results show that selectively introduced
microstructures enable an increase in the thickness of the lubricating film and the
bearing capacity of the lubricant film. The optimum size of a structure is determined
by the relative sliding velocity. It is also advisable to avoid orienting the linear
extension of rotationally symmetrical structures crosswise to the sliding direction.

Another positive result of laser structuring is evident in the field of internal

combustion engines [Li, Kli]. Laser-structured cylinder faces enable the customer to
enjoy such benefits as reduced oil consumption, improved emissions, reduced wear,
higher efficiency due to lower friction losses, a reduction in HC emission and greater
flexibility with respect to piston ring equipment. According to [Kli], there are plans to
use this technology on a car manufacturer's engine production line.
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0 ,5 m m

Fig. 5: Ceramic sliding ring

Laser beam structuring is being used to work microstructures (dimples) into both
ceramic and metallic surfaces at the Fraunhofer IPT. One example of a ceramic
sliding ring surface structured with a 1.2 kW CO2 laser is shown in Fig. 5.

Fig. 6: REM image, dimples in steel material

The crater-like shape of the structures are clearly visible in Fig. 5 and Fig. 6. The
photographs in Fig. 5 were taken after the ceramic axial face seal had been
finished/polished, removing the molten deposit and establishing the surface micro-
topography. The CO2 laser system at the disposal of the Fraunhofer IPT is capable of
producing recesses down to a minimum of around 120 µm in diameter and approx.
10 µm deep in ceramic materials. Considerably smaller recesses can be achieved in
steel surfaces using solid-state lasers. The shape of the micro-lubricating recess can
be approximated by paraboloids of revolution, which means that finer geometries can
be worked by removing material during the last machining process, when the surface
is polished.
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Fig. 6 shows the dimples that have been worked into a steel surface with a pulsed
solid-state laser and the very low rate of molten residue left behind thanks to the
optimised process parameters. Although there is a significant reduction in the molten
deposit, expedience dictates that the manufacturing process must be modified so
that preliminary machining and laser structuring take place before the
finishing/polishing operation.

Strategy
A holistic examination of tribological systems gives rise to a new approach which,
apart from the material-specific structural constitution and the chemical composition,
regards the functional design of the contact surface as a means of optimisation that
is independent of the material to the greatest extent possible.

The pursued tribological approach follows the hydrodynamic sliding bearing theory,
as well as the theory concerning the contact between solid bodies. Friction and wear
are generally determined by the size of the micro-contact surface and the number of
points of contact [Me]. The larger the contact surface between the mating tribological
components, the lower the amount of impressed stress or extension, reducing the
likelihood of reaching the critical stress/extension at which point the material is
weakened as a result of removal or crack growth. A surface with a high percentage
contact area therefore exerts a positive influence on the tribological system
performance [Ne]. The orientation of the asperities of roughness can also be used to
advantage with respect to building up a bearing pressure if the asperities are aligned
so as to be mutually perpendicular with the direction of fluid flow [De, Pa, Jo, Pe].
This effect is countered by the wear phenomena that can be attributed to the
adhesion tendencies of the mating materials. These are particularly apparent when
the contact surfaces are pressed together with high pressure and they are no longer
separated by a fluid fissure. The demand for a high percentage bearing area must
not therefore be equated with the demand for an elimination of roughness.

An adequate supply of fluid is an essential prerequisite for establishment of a

lubricating film that has no interruptions across the surface and can be deepened. An
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increase in the thickness of the lubricating film results in favourable operating

conditions in the area of mixed friction with a greater proportion of the hydrodynamic
friction which is lower than the dry friction. This reduces wear on the tribological
partners. The fluid separates the surfaces of these components completely in the
perfect lubrication zone.

Laser technology
Generally speaking, there are a number of different manufacturing methods available
to create dimple structures, e.g. removing material by means of abrasive blasting,
erosion or ultrasonic machining. However, the combination with a plateau surface is
best achieved using laser technology. Modified by laser beam, the functional surface
has a surface fraction with global plateau character, as well as a reproducible,
regular arrangement of identical local micro-lubricating recesses. The diameter,
depth and distribution of these recesses can be adapted according to the load for the
respective application. The high processing speed - more than 1000 micro-lubricating
recesses can be produced per second - also makes laser structuring suitable for
large areas or series production [Kl-3].

Laser-beam sources have become established in industrial material processing

applications for some time now. Laser is being used as a flexible tool to an increasing
extent in the fields of welding, cutting, inscribing and surface treatment, e.g. coating
or hardening, and is characterised by the following properties:

- good focussing capacity (according to laser principle and lens),

- high energy density,
- inertia-free tool for flexible manipulation,
- contactless tool, so no wear,
- high processing speed,
- high reproducibility,
- high processing flexibility,
- easy to control,
- easily integrated into machine tools and existing process chains,
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- the process has a low environmental impact,

- little thermal influence on the substrate.

As machining geometries become more diminutive, laser beam is now superseding

many conventional machining methods and is enabling the development of new
techniques. One comparatively recent method of surface treatment is laser-beam
structuring, whereby structures are selectively worked into a surface by means of
laser-beam ablation. This technique can be used to produce defined micro-lubricating
recesses in tribologically loaded functional surfaces by means of a pulsed laser
beam. The Fraunhofer Institute for Production Technology IPT is currently using CO2
and Nd:YAG lasers for this purpose. The crater-like structures produced during this
process are primarily influenced by the geometry, the intensity distribution of the
laser beam over the surface of the workpiece and the process parameters, e.g. pulse
duration and focal position of the laser beam, as well as the motion characteristics of
the workpiece during the machining process. An important role is also played by the
material. The diameter, depth and distribution of the micro-lubricating recesses can
be adapted according to the load for the respective application.

As shown in Table 1, the structuring possibilities are essentially determined by the

laser-beam source. Excimer lasers are capable of producing virtually any structures
in the surface of the workpiece using a mask projection system. They can produce
structures measuring just a few micrometers. However, the low ablation capacity of
this type of laser must be regarded as being one of the most significant
disadvantages of excimer-laser structuring. A pulsed laser beam can be used to
produce tribologically effective micro-cavities quickly and flexibly [Kl-1]. CO2 and
Nd:YAG lasers offer the most expedient solutions for industrial applications because
of their high material removal rates and the associated cost-effectiveness of the
process, but they are unable to produce such small-sized structures. The structuring
process using CO2 or Nd:YAG lasers is described in greater detail below.

Laser materials processing is oriented to the fundamental concept of using high-

energy electromagnetic radiation for the selective machining of a workpiece. This
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involves guiding the pulsed beam onto the surface of the workpiece in a defined
manner and using lenses to form the beam to achieve the required power density and
distribution. The beam is absorbed in the workpiece or on its surface to produce the
desired effect on the material; this means, for example, that the energetic influence
exerted on the material by Nd:YAG and CO2 lasers is achieved by heat, Fig. 7.
Various interactive processes take place according to the intensity and structure of
the material and these can be used to dimension the process. Among other things,
the pulsed mode of operation enables realisation of intensities of up to 1012 W/cm2
with very short pulse times (µs to fs).

Laser system Pulse Max. power Repetition Wavelength Pulse

energy rate duration
Nd:YAG laser 0.1-
70 J 300 W 1-300 Hz 1064 nm
20 ms
Diode-pumped
Q-switched 135 µJ 6W 0.5-50 kHz 1074 nm 25 ns
Nd:YLF laser
Diode-pumped 1 mJ 1064
Nd:YAG laser 520 µJ 532
0,5 W 1-500 Hz 30-50 ps
280 µJ 355
100 µJ 266
Titanium 780 nm
200 mJ 2W 10 Hz 150 fs
sapphire laser 390 nm
TEA CO2 laser 0.18-50 J 5 kW 30 kHz 10.6 µm 6 µs
Excimer laser 308 nm
248 nm
10 J 1 kW 1-300 Hz 10-30 ns
193 nm
157 nm

Table 1: Laser systems and parameters for laser-beam ablation [Wei99]

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Gas
Laser 3.
strahl
Sublimier-
1. ter Werk-
Schmelze
stoff 5.
4.
Werkstück
2. 6.
Laser-
brennfleck

Fig. 7: Principle of the laser-beam ablation process

[Legend: 1. Laser beam, 2. Workpiece, 3. Gas, 4. Molten material, 5. Sublimed
material, 6. Laser focal point]

There are various material removing mechanisms that are used by the different laser-
beam sources: CO2 and solid-state lasers (Nd:YAG) are capable of using two
different mechanisms according to the process management. With laser-beam
ablation, the energy inserted into the material by the laser converts it into a molten
phase and a flow of gas blows it out of the machining zone. This technique is
characterised by high material removal rates and an average surface quality.
Increasing the intensity of the beam causes the material to be vaporised directly,
removing material by means of sublimation to produce finer structures with better
surface precision but with lower removal rates. The volume percent of molten
material / vapour produced depends on the material-specific properties and the
chosen process parameters, such as laser-beam intensity, wavelength and pulse
duration. The removing capacity and removal rate of a material is not influenced by
its hardness, but by such factors as absorption, thermal conductivity or thermal
capacity. This is why a laser beam is also capable of machining materials that are
difficult to cut (carbides, ceramics, diamonds). [Tön93, För01, Eic01, Kön97].
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With the types of laser and mechanisms described above, the laser beam may be
guided over the surface of the component by means of a scanner or a direct-beam
optical system, whereby the chosen system is determined by the application.

Direct-beam optical system

When the direct-beam optical system - Fig. 8 - is used, the unprocessed laser beam
is directed via water-cooled mirrors in the work centre to the ablation head, where it is
focussed using a zinc selenide lens and leaves the gas nozzle through a central
aperture. The adjusting unit offers a means of moving the lens, which is vertically
fitted into an adapted lens holder within the ablation head. This ensures that the focal
position can be varied relative to the workpiece while maintaining a fixed distance
between the bottom edge of the nozzle and the surface of the workpiece. The
distance between the nozzle and the surface of the workpiece can also be altered by
moving the ablation head and adjusting the position of the lens accordingly. Leaving
the supply line, the process gas flows into the pressure chamber of the nozzle unit.
The lens fitted in the lens holder seals the pressure chamber so that no gas can
escape upwards, which means that the process gas can only leave the chamber
through the gas nozzle. Nozzles of different geometries may be fitted to vary the
shape of the gas jet. the coupling element is used to secure the ablation head to the
beam guidance system. The workpiece or complete lens system must be moved if
the direct-beam optical system is to be used for 2-dimensional or 3-dimensional
machining.
Adjusting
unit
Nozzle
unit

Coupling
element

Nozzle Lens

s holder

Fig. 8: Direct-beam optical system

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Scanner systems
Fig. 9 shows various scanner systems. These are tilting or revolving mirror systems.
Tilting mirror systems are also referred to as galvanometer scanners. Both of these
systems use special lenses to shape the unprocessed beam. The different deflection
mechanisms enable the laser beam to be moved within a so-called scanner field. The
factors affecting the size of the scanner field include the focal distance and the
required diameter of focus. A flat-field lens is used to ensure that the laser beam is
as perpendicular as possible when it meets the surface of the component.

a Laser beam
b Focussing lens
c Revolving mirror
d Drive
e Tilting mirror

Fig. 9: Scanner optical system / LFT/

Compared with revolving mirrors, galvanometer scanners are capable of much higher
traversing speeds and therefore have higher advance rates for the laser beam. A
revolving mirror system, on the other hand, is more rugged and has a larger scanner
field for a comparable focal distance.

The scanner systems usually have a larger laser-beam focus diameter than the
direct-beam optical systems, which means that they produce larger structures than
those produced using a direct-beam optical system. Direct-beam optical systems are
capable of manufacturing structures measuring as little as 10 µm with short focal
distances (< 20 mm) and good beam quality.
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The form, size, depth and arrangement of the micro-lubricating recesses depend on
the process parameters shown in Fig. 10. The geometry of a recess structure is
primarily influenced by the diameter of the laser beam on the working plane, the
shape of the beam and the pulse duration. The way in which the focal position
influences the geometry of the micro-lubricating recess is shown by way of example.
The length and width of these recesses are proportional to the beam diameter for the
respective focal distance, whereas the depth is determined by the energy density of
the laser beam. The structure produced with zF = -0.8 mm as the focal position is
particularly remarkable. The intensity distribution of the laser beam is clearly
projected as surface topography.

Workpiece
handling
Machine Workpiece
Positioning Surface
dynamics Material
Repeating Absorption
accuracy topography
accuracy coefficient
Result
structuri
of
Laser ng Process
parameters parameters
Distance nozzle to
Laser Nozzle
Wavelengt workpiece
Pulse Process gas
capacity geometry
Pulse Type of process
energy pressure
Intensity Focal
duration gas
distribution position

100
µm
zF=-0,8
mm zF=0
mm
zF=-0,4 -

mm +
Focu zF=+0,4
s mm
Processing
Laser CO2 ,1200 zF=+1,0
parameters:
Process N2
:Nozzle W
1,2 mm
gas:
Pulse 70
clearance: mm Caustic surface
Gas 5 the CO2 laser
duration: µs of
pressure: bar beam

Fig. 10: Process parameters

The pulse duration also exerts a considerable influence on the geometry of the
micro-lubricating recess, whereby the depth of the recess increases logarithmically
with the pulse duration, Fig. 11. Allowed to take effect for a longer period, the
resulting increase in radiant power causes more energy to be coupled into the
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workpiece, extending the zone of influence due to the effects of thermal conduction.
Because of advance motion during the pulse time, the length of the micro-lubricating
recess, i.e. the diameter in the advance direction, is generally greater than its width
as the laser beam travels a defined path on the workpiece during the pulse period.

0,7 Material: Si3 N4 (SSN)

Laser: CO2 , 1200 W Pulslänge: variabel Structural geometry
mm Schutzgas: N 2 Gasdruck: 5 bar
Düsenabstand: 1,2 mm Brennpunkt: +0,4 mm
0,5 Material: Si3N4 (SSN)
Tiefe
Laser: CO2,1200 W
Strukturgeometrie

0,4 Breite
Länge
0,3 Protective gas: N2
Nozzle clearance: 1.2 mm
0,2
Pulse duration: variable
0,1
Gas pressure: 5 bar
0
10 50 100 500 µs 1000
Focal point:+0.4 mm
Pulslänge

Fig. 11 : Influence of the pulse duration

Process analyses

The first stage of the process analyses involves producing micro-lubricating recesses
on test components. In the course of this, the technological relationships between the
target variables, such as depth, size and shape of the micro-lubricating recess are
determined, as well as the process characteristics and process parameters. The
process parameters to be investigated are as follows:

- laser-beam pulse duration,

- laser power / energy,
- intensity distribution of the laser beam,
- focal position,
- type of process gas and pressure,
- nozzle geometry,
- motion characteristics of the workpiece,
- material and surface structure
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The surfaces of test components will be laser structured on the basis of the findings
and these test components will then undergo tribological analysis. Specific
processing strategies are being developed for this, which will be assessed with
particular attention focussed on the processing time and the quality of the results.
The produced surface structures will be recorded by means of optical measuring
instruments and characterised using a scanning electron microscope.

Tribological analyses

Experiments will be conducted to determine the functional influence exerted by

structured surfaces. The loads applied under real operating conditions are
determined for this purpose and these are modelled in friction measuring instruments
in various degrees of abstraction according to [Ha]. The experiments required for this
will be conducted in test rigs that will be developed or modified for the respective load
within the framework of the research project. The three-dimensional tactile surface
measuring technique will be used to register and measure wear damage. Tribological
modelling captures the change to the system characteristics as a result of structuring
the test components as a function of the load collective. The improvement potential
can be used to the point of achieving optimum microstructures by means of
subsequent variations to the structuring. The micro-structural variations are examined
efficiently in model experiments with simple, component-like test objects and a load
collective similar to that encountered under normal operating conditions. Model
specimens that have identical characteristics but no micro-lubricating recesses are
used as reference samples.

The following factors exert a considerable influence on the experiments:

- component material,
- topography of the surface fractions that have not been laser-structured,
- geometry of the micro-lubricating recesses,
- number of micro-lubricating recesses per unit of area,
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- distribution of the micro-lubricating recesses over the functional area,

- load on the contact surface (form of motion, relative velocity, normal tension,
temperature, load period, fluid).

An optimisation process is followed by the transposition to real components and a

tribological analysis of these. The new micro-structured surfaces should finally be
fitted into a demonstrator and tested in practice within the framework of a pilot
application. The pilot application will be specified on the basis of the findings from the
basic research within the attendant industrial working committee.

Summary
The aim of laser-structuring tribological contact surfaces is to reduce wear rates and
frictional losses in hydraulic systems. Design and manufacturing parameters are
being optimised in an effort to support the formation of hydrodynamic bearing films in
tribological contacts and effect a shift in the direction of lower relative velocities. In
the past, tribological optimisation has been achieved by means of microstructures on
ceramic sliding rings. The use of laser technology enables the efficient, flexible and
reproducible creation of microstructures against a background of integration into
existing manufacturing processes.

Credits
The financial backing for the "Improved wear and friction performance of hydraulic
components using laser-structured contact surfaces – TriboStruk" is being made
available from private-enterprise funds provided by the "Industrial Research
Foundation". We would like to take this opportunity to thank the foundation for its
prompt, unbureaucratic support. The project also received financial backing in the
form of contributions made by the member companies of the Fluid Technology
Research Fund within the VDMA.
O + P »Ölhydraulik und Pneumatik« 46 (2002) Nr. 9 20

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