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(a) Both PTFE/Pyrrolidone and PEEK/PTFE coatings showed low friction coefficient in the range of 0.02 – 0.035 under aggressive fretting contact conditions up to 43 MPa nominal contact pressure. Under higher contact pressure, PEEK/PTFE coating scuffed at 133 MPa contact pressure, while PTFE/Pyrrolidone did not show any catastrophic failure up to 166 MPa contact pressure. (b) The tribological performance of the polymeric coatings under fretting conditions was greatly influenced by the ability of the polymers to form a transfer film on the metal pin counterface. The pin surface tested with PTFE/Pyrrolidone showed a continuous and stable transfer film, while in the case of PEEK/PTFE, only small amount of material was transferred to the counterface, thus exposing hard metal asperities on the contact interface. (c) Transfer film formation was initiated by interlocking of polymer wear debris within the counterface asperities, thus gradually smoothening and filling the rough pin surface with transferred polymer material. Most of the wear of the polymer film occurred during this initial process of transfer film formation. Once a stable transfer film was formed on the counterface, it acted as a lubricating layer on the interface by protecting the soft polymers from further damage by hard and sharp metal asperities on the counterface. Therefore, PTFE/Pyrrolidone coating which formed a stable transfer film on the counterface did not show any catastrophic failure even after the coating was worn out. (d) The addition of liquid lubricant on the contact interface in the presence of the polymeric films was not tribologically beneficial. Specifically under such more complex interface conditions, higher wear was measured compared to the 126PDF Image | TRIBOLOGY OF POLYMERIC COATINGS FOR AGGRESSIVE BEARING APPLICATIONS
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