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To obtain higher contact pressure, reduced diameter pins (3.2 mm) were used in another set of fretting tests as shown in Figure 6.6. The same loading profile as used for the regular pins was used, resulting in higher nominal contact pressure up to 165.8 MPa (at the maximum normal load of 1334 N). Even under this high contact pressure condition, the PTFE/Pyrrolidone coating still did not show any scuffing behavior with only smooth and gradual increase of the COF for the last 6 min - 8 min of testing. At the end of the test, its COF was maintained at 0.05-0.06 which was still relatively low. In the case of PEEK/PTFE coating, however, scuffing was clearly observed with a sharp increase of COF at 133 MPa contact pressure as shown in Figure 6.6(b). This sudden increase of the COF was caused by direct metal (pin)-to-metal (substrate) contact when the polymer coating layer was completely penetrated, which is also seen in the worn coating surface in Figure 6.6(d). Significant amount of wear debris is observed in the vicinity of the wear track of the PEEK/PTFE coating. Although less wear debris was observed in the case of PTFE/Pyrrolidone shown in Figure 6.6(c), this coating was also found to be penetrated after profilometric measurements. Thus, both PTFE/Pyrrolidone and PEEK/PTFE coatings were penetrated under these more aggressive testing conditions, but only the PEEK/PTFE coating exhibited clear scuffing behavior with catastrophic failure at a scuffing pressure of 133 MPa. This implies that in the case PTFE/Pyrrolidone, even though the coating is penetrated, there is a lubricious layer on the interface between the pin and the substrate which prevents direct metal-to-metal contact, thus avoiding scuffing failures. Further investigation of this layer is discussed in section 6.3.2. 113PDF Image | TRIBOLOGY OF POLYMERIC COATINGS FOR AGGRESSIVE BEARING APPLICATIONS
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