Fundamentals of Interfacial Tribology and Applications to Manufacturing Processes

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The productivity, product quality, and environmental sustainability of Canada's manufacturing sectors are closely linked to their ability to remain at the forefront of new material development and the use of efficient manufacturing processes. Tool wear, built up edge formation, and adhesion are among the factors that influence a manufacturing process's efficiency and surface quality of the machined or formed part. It is also important to control of a material's microstructure at each stage in the manufacturing process as it is often the microstructure of the near surface region that dictates the product's manufacturability performance. The proposed program aims at developing new tribological methods that will increase efficiency of manufacturing processes, particularly machining and forming of engineering components made of lightweight alloys. The material systems that will be studied will consist of Al and Mg alloys that are of critical importance for fuel economy conscious transportation sectors. The microstructural aspects of surface and interface damage mechanisms will be examined by undertaking experimental and computational studies. The research will consist of two related programs: A 'Tribology of Sheet Metal Forming' program that will delineate coefficients of friction and contact damage mechanisms between Al, and Mg alloy sheets and die surfaces in order to increase their formability and surface quality. A Tribology of Machining' program that will focus on improving the efficiency of cutting and drilling operations of light metal castings typically hindered by material adhesion. Each of these two programs has unique research requirements, yet the fundamental issues are similar and can be addressed using a common research methodology that will include:i) the development of new testing methods to simulate interfacial tribo-chemical failure mechanisms that occur during manufacturing conditions; ii) the delineation of wear, adhesion and friction mechanisms from microstructural and atomistic points of view;iii) the design of interfaces-- using new coatings, solid lubricants, textured surfaces-- to increase formability of lightweight sheet metals and effectiveness of machining processes using the results of experimental and computational work. In summary, the research program will generate fundamental scientific and engineering knowledge to produce new energy efficient manufacturing technologies and improve quality of lightweight components. The research proposal is structured to provide the highest possible output of HQP who will utilize the new technology and enhance Canada's ability to compete in the global economy.