Professional Documents
Culture Documents
State of the Art in Laser Surface This idea was promoted mainly for parallel sliding, as is the case
in mechanical seals 关7,8兴. An etching technique was used for the
Texturing texturing, and both theoretical and experimental work was per-
formed in an attempt to optimize the texturing dimensions. Thirty
years later, in 1996, Etsion and Burstein 关9兴 presented a model for
Izhak Etsion mechanical seals with regular micro-surface structure, showing a
e-mail: etsion@tx.technion.ac.il substantial improvement in seal performance when evenly distrib-
Department of Mechanical Engineering, Technion, uted hemispherical micro-dimples are present on one of the mat-
Haifa 32000, Israel ing seal faces. The work in 关9兴 was followed by an experimental
study 关10兴 in which laser-textured seal rings were tested in oil
showing that the spherical dimple shape can be optimized and that
an optimum dimple depth over dimple diameter ratio exists
Surface texturing has emerged in the last decade as a viable op- that maximizes the film stiffness and the PV factor at seizure
tion of surface engineering resulting in significant improvement in inception.
load capacity, wear resistance, friction coefficient etc. of tribo- As can be seen from the discussion above various forms of
logical mechanical components. Various techniques can be em- surface texturing can be used for enhancing tribological perfor-
ployed for surface texturing but Laser Surface Texturing (LST) is mance. However, of all the practical micro-surface patterning
probably the most advanced so far. LST produces a very large methods it seems that laser surface texturing 共LST兲 offers the
number of micro-dimples on the surface and each of these micro- most promising concept. This is because the laser is extremely fast
dimples can serve either as a micro-hydrodynamic bearing in and allows short processing times, it is clean to the environment
cases of full or mixed lubrication, a micro-reservoir for lubricant and provides excellent control of the shape and size of the micro-
in cases of starved lubrication conditions, or a micro-trap for dimples, which allows realization of optimum designs. By con-
wear debris in either lubricated or dry sliding. The present paper trolling energy density, the laser can safely process hardened
reviews the current effort being made world wide on surface tex- steels, ceramics, and polymers as well as crystalline structures.
turing in general and on laser surface texturing in particular. It Indeed, LST is starting to gain more and more attention in the
presents the state of the art in LST and the potential of this tech- Tribology community as is evident from the growing number of
nology in various lubricated applications like mechanical seals, publications on this subject.
piston rings and thrust bearings. The paper also describes some The purpose of this paper is to review various forms of surface
fundamental on going research around the world with LST. texturing in general and the laser surface texturing in particular.
关DOI: 10.1115/1.1828070兴 Extensive experience that has been accumulated since 1996 with
LST, mainly in mechanical seals, will be described as well as the
on going research and development work for other applications
like piston rings and thrust bearings.
Introduction
Surface texturing as a means for enhancing tribological proper-
ties of mechanical components is well known for many years.
Perhaps the most familiar and earliest commercial application of
surface texturing is that of cylinder liner honing 关1,2兴. Today sur- Surface Texturing in Tribology
faces of modern magnetic storage devices are commonly textured Various forms and techniques of surface texturing were devel-
关3,4兴 and surface texturing is also considered as a means for over- oped over the years for enhancing Tribological performance. The
coming adhesion and stiction in MEMS devices 关5兴. Fundamental vibrorolling method was developed by Schneider in 1984 关11兴, it
research work on various forms and shapes of surface texturing consists of producing shallow grooves by plastic deformation us-
for tribological applications is carried out by several research ing a hard indenter on metallic parts. An extensive work has been
groups worldwide and various texturing techniques are employed done on vibrorolling in Eastern Europe 关12兴 that somehow went
in these studies including machining, ion beam texturing, etching unnoticed in the western world. At about the same time Suh and
techniques and laser texturing. Interestingly almost all these fun- co-workers 关13兴 in the U.S. presented the idea of modulated sur-
damental works are experimental in nature and most of them are face for removing oxide wear debris from the interface of electri-
motivated by the idea that the surface texturing provides micro- cal contacts. They initially used an etching technique which was
reservoirs to enhance lubricant retention or micro-traps to capture later replaced by abrasive machining to form grooves 关14 –17兴
wear debris. Usually, optimization of the texturing dimensions is that they termed undulated surfaces. Like in 关13兴 the function of
done by a trial and error approach. the undulations is to act as traps for wear debris thereby reducing
Hamilton et al. presented in 1966 关6兴 surface texturing in the the ploughing and deformation components of friction and wear.
form of micro-asperities that act as micro-hydrodynamic bearings. Reactive ion etching 共RIE兲 was employed by a group lead by
Kato in Japan 关18 –20兴 to study the effect of surface texturing, in
Manuscript received December 18, 2003; revision received August 11, 2004. Re- the form of micro-dimples, on parallel sliding faces of SiC in
view conducted by: L. S. Stephens. water. Other techniques include Abrasive jet machining 关21兴,
248 Õ Vol. 127, JANUARY 2005 Copyright © 2005 by ASME Transactions of the ASME
LIGA 关22兴, and lithography and anisotropic etching 关23兴. Table 1 second lasers 关28 –32兴. This work is mainly aimed at studying the
summarizes these various techniques and shows the global spread texturing process itself however, limited basic Tribological tests
of interest in surface texturing. are also performed in collaboration with researchers at other in-
Most of the work described above is experimental, using vari- stitutions like CSEM in Neuchatel, Switzerland and elsewhere. In
ous types of pin on disk and ring on ring test machines. This is 关29兴 for example, a ball-on-disk test is described where a small
probably due to the fact that the involved phenomena are very fixed amount of lubricant is provided and the evolution of friction
complex, and only in limited cases can be described analytically. coefficient with sliding distance is monitored. The lifetime of a
However, in spite of the lack of extensive theoretical modeling sample was defined as the distance at which friction starts to in-
and optimization of the texturing dimensions, remarkable im- crease rapidly. It was found that the lifetime of LST sample disks
provement in terms of friction and wear reduction was demon- could be eight times longer than that of untextured samples.
strated in these experiments with various texturing forms. A fundamental research work on LST is carried out at Argonne
National Laboratory in the USA. The effect of LST on the transi-
Laser Surface Texturing „LST… tion from boundary to hydrodynamic lubrication regime was ex-
perimentally investigated 关33兴 by measuring friction and
Laser surface texturing has been used for over 10 years now in electrical-contact resistance in a pin-on-disk unidirectional sliding
the magnetic storage industry 关3,4兴 mainly to prevent stiction dur- conformal contact. LST was observed to expand the range of the
ing start up. This issue will not be dealt with in the present review. hydrodynamic lubrication regime in terms of load and sliding
Instead, the potential of LST in enhancing Tribological perfor- speed. Furthermore, LST was observed to reduce the friction co-
mance during continuous operation will be described. efficient substantially under similar operating conditions when
A large amount of work on laser surface texturing was done in compared with untextured surfaces.
Germany starting some 10 years ago. Unfortunately, most of it is As with the nonlaser texturing techniques of the previous sec-
published in the German language and hence, is not even refer- tion, the entire laser texturing works described above are experi-
enced in English archive journals. A few exceptions are papers mental when it comes to investigation of the tribological aspects
coming from the group lead by Geiger at the University of of LST. A trial and error approach is adopted whenever optimiza-
Erlangen-Nuremberg e.g. 关24,25兴. This group uses an eximer laser tion of the texturing dimensions is attempted. This is probably the
with a mask projection technique, a mask is illuminated with the reason for the large variations in ‘‘optimum’’ dimensions obtained
laser beam and its geometrical information is projected onto the by different groups. The trial and error approach may be the only
textured surface. This method was applied to a punch, used in a viable one in cases like dry sliding or starved lubrication where
backward cup extrusion process for the production of rivets, and basic theoretical modeling does not exist. In these cases the LST
showed a substantial increase of up to 169% in cold forging tool micro-dimples usually function as micro-traps for wear particles
life. An interesting discussion regarding the combination and or- or micro-reservoirs for lubricant retention. However, in other
der of hard coating and laser texturing is included with the con- cases, where the micro-dimples function as micro-hydrodynamic
clusion that for the specific case in hand coating prior to texturing bearings, a thorough theoretical investigation can be performed to
was preferable. Another German paper that was translated to En-
glish in 2002 关26兴 provides a good review of LST work done in
Germany including applications such as mechanical seals and cyl-
inder liners for internal combustion engines. This paper also de-
scribes different laser systems used for surface texturing but con-
centrates on CO2 and Nd:YAG lasers.
A CO2 laser was used at Tohoku University, Japan 关27兴 to tex-
ture SiC surfaces for studying the effect of LST on the transition
from hydrodynamic to mixed lubrication regime. Experiments
were carried out with a disk and a cylinder configuration loaded
axially under water lubrication. Surface texture in the form of
micro-pores with a diameter of 150 m and a depth of about 8 –10
m was tested and compared with untextured specimens. It was
found that the critical load for the transition from hydrodynamic
to mixed lubrication in the case of the textured specimens was
20% larger than that for the untextured faces.
An extensive research work on laser surface texturing is being
done at the Institute of Applied Physics of the University of Bern Fig. 1 LST regular micro-surface structure in the form of
in Switzerland utilizing Q-switched Nd:YAG but mostly femto- micro-dimples
Fig. 3 Comparison of the friction torque versus face loading Fig. 5 Friction torque versus sealed pressure for nontextured
for textured and nontextured SiCÕ SiC seals in water †35‡ and partial textured seals †37‡
Seal 74 BW 2002539, Borg-Warner Fig. 8 Typical pressure distribution in three slider bearing
Seal materials Tungsten carbide against carbon configurations of: 1-plane slider, 2-stepped slider, 3-surface
enriched with silicon textured parallel slider
Seal diameter 55 mm at shaft
Pump 128-3507A, Byron-Jackson
Fluid pumped C9–C10 hydrocarbons
Vapor pressure 7.25 bar
Viscosity 0.175 cp
Operating temp. 350°C
Pressure at the seal 4 –5 bar.
The LST treated seal operated for more than 10 000 h over a 38
month period before it was replaced because of an O-ring failure.
Over the same time, the untreated seal had to be replaced four
times. Gadiv found the following:
1. Failure of the seal was caused by the melting of the O-ring
of the stationary tungsten seal ring as a result of exposure to high
temperature;
2. The LST tungsten carbide ring was still in perfect and op-
erational condition. The flatness at the contact surface of the ring
was within 1 m and the flatness outside the contact surface was
0.25 m;
3. The carbon ring, with a waviness of 3– 4 m, could be re-
assembled after re-polishing/lapping; Fig. 9 A comparison of friction coefficient of partial bidirec-
4. The wear rate of the tungsten carbide ring was just 1 m for tional and unidirectional LST bearings, and a baseline untex-
10 000 h of operation. LST increased the life of the seal threefold. tured bearing at 1500 rpm †46‡
In addition, the average savings gained from using the LST- LST in Dry Contact Applications
treated seal were in the region of US $900 per year.
As was demonstrated with the undulated surfaces 关13–17兴 sur-
face texturing can reduce friction and wear by trapping loose wear
particles. The potential benefit of LST in providing micro-traps
LST in Other Lubricated Applications for wear debris in dry contacts subjected to fretting has been dem-
onstrated in 关48兴 and 关49兴. The results in 关48兴 showed that the
The potential benefits of applying LST to piston rings has been escape of oxide wear debris into the LST micro-dimples resulted
demonstrated theoretically 关41兴 and experimentally in laboratory in up to 84% reduction in the electrical contact resistance of the
tests 关42兴. Optimum texturing parameters for minimum friction textured fretting surfaces compared to the case with nontextured
force were found in 关41兴 for full LST rings showing a potential surfaces. The potential effect of LST on fretting fatigue life was
reduction of about 30% compared to nontextured rings under full demonstrated in 关49兴 by conducting a limited number of fretting
lubrication conditions. Good agreement was found with experi- fatigue tests. The LST allowed an easier wear debris escape from
mental results in 关42兴 共see Fig. 6兲. In addition it was found that the fretted zone into the micro-dimples thus, improved the fretting
optimum LST is beneficial under starvation as well, where the fatigue resistance and almost doubled the fretting fatigue life.
dimples serve as micro-reservoirs for lubricant. Figure 7 presents
experimental results 关42兴 with full LST applied to specimens
simulating piston rings, where the conditions were varied from Summary
full to starved lubrication by controlling the lubricant flow rate to Surface texturing in general and laser surface texturing in par-
the sliding contact. This was done by drip lubrication while vary- ticular has emerged in recent years as a viable means of enhancing
ing the time between successive drops. The results show the ben- tribological performance. A great deal of fundamental research
efits of LST in reducing friction in both full 共30 s between suc- work is still going on worldwide, utilizing various texturing tech-
cessive drops兲 and starved lubrication conditions 共260 s between niques, to explore the benefits of surface texturing and to optimize
successive drops兲. the texturing forms and dimensions under various operating con-
The use of laser texturing in the form of micro-grooves on ditions. Some very recent additional publications on relevant work
cylinder liners of internal combustion engines was presented at can be found in 关50–52兴. Of all the practical micro-surface pat-
the 14th International Colloquium Tribology in Esslingen 共see terning methods it seems that laser surface texturing 共LST兲 offers
关43兴 for example兲 showing lower fuel consumption and wear. This the most promising concept. This is because the laser is extremely
technique called ‘‘laser honing’’ is now commercially available fast, clean to the environment and provides excellent control of
from the Gehring Company in Germany 关44兴. the shape and size of the micro-dimples, which allows realization
Analysis of LST in hydrodynamic thrust bearings of the sim- of optimum designs. Table 2 presents a list of centers and organi-
plest form of parallel sliding disks 关45兴 has shown the potential of zations around the world that are active in LST. As can be seen
LST in this application. These simple bearings are usually found LST is starting to gain more and more attention in the Tribology
in magnetic drive seal-less pumps were the process fluid serves as community as is evident from the growing number of publications
the lubricant for the pump bearings. It was found that partial LST on this subject.
can improve substantially the load carrying capacity of these At the same time LST is already successfully applied to cylin-
simple bearings and make them comparable to more sophisticated der liners and to mechanical seals resulting in up to threefold
tapered or stepped sliders. The concept of generating load carry- increase in seal life in pumps operating in the field 关53兴. This
ing capacity with partial LST is demonstrated in Fig. 8. The tex- success is attributed to the theoretical modeling of LST under full
tured portion of the slider provides an effective larger clearance fluid film conditions, which gave good agreement with laboratory
than the non-textured portion and hence, the slider is acting as a tests and permitted optimization of the LST parameters. It is en-
stepped slider. Test results in water at 1500 and 3000 rpm 关46兴 visaged that with the continuing R&D effort many more mechani-
showed that the textured bearing operated with a clearance that is cal components in tribological applications may benefit from LST
about 3 times larger and friction that is about 3 times smaller 共see in the coming years.
Fig. 9兲 than the case of the nontextured bearing throughout the
range of tested loads.
Laser texturing is also used extensively in metal forming as a References
mean for a secondary hydrodynamic lubrication mechanism 关1兴 Jeng, Y. R., 1996, ‘‘Impact of Plateaued Surfaces on Tribological Perfor-
mance,’’ Tribol. Trans., 39共2兲, pp. 354 –361.
which is called micro-pool or micro-plastic hydrodynamic lubri- 关2兴 Willis, E., 1986, ‘‘Surface Finish in Relation to Cylinder Liners,’’ Wear, 109,
cation 关47兴. More work in this area can be found in the references pp. 351–366.
list of 关47兴. 关3兴 Ranjan, R., Lambeth, D. N., Tromel, M., Goglia, P., and Li, Y., 1991, ‘‘Laser