Tribological transfer mechanisms and large area micro-contact simulation of solid lubricant supply from PVD layers for dry running gear stages

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The proposed second funding period of the project "Tribological transfer mechanisms and large-area microcontact simulation of solid lubricant supply from PVD coatings for dry-running gear stages" aims to investigate the transient loads in exclusively solid-lubricated, highly loaded gear stages within the DFG priority program 2074 "Fluid-free lubrication systems with high mechanical loads". In the first funding period, model- and gear analogy tests were carried out to systematically investigate coating and substrate material combinations, so that a database exists regarding the tribological behaviour of promising variants. In particular, two-layer coating systems based on MoSX and deposited by high power impulse magnetron sputtering (HPPMS) showed tolerable surface pressures of up to 1.6 GPa in the tooth flank analogy test, with a reduction of the friction coefficient to 0.02. The planned activities within 4 work fields are therefore targeted on a further development of the systems and the identification of additional effects in the real tribological system "gear". On the one hand, this includes the production, coating and initial characterisation of test specimens in work field 1, which are tested and characterised in detail in work field 2. The focus is on tests on the gear test rig in combination with a wear analysis, supplemented by high-temperature measurements of the mechanical coating properties and analyses of the fatigue resistance under cyclic loading. The third field of work extends the microcontact simulation of the first funding period, with a special focus on the contact properties of dry-running tooth flanks. In work field 4, the results from the first and second funding periods are combined in order to identify additional effects in the tooth flank contact on the one hand and to derive strategies and evaluation criteria for the use of solid lubricated systems on the other. At this point, there is an interaction with the other projects of the priority programme in order to increase the comparability of this type of lubrication systems.