1. Micro-textured Engineered Surfaces
Specific Challenge
REDUCE ENERGY LOSSES DUE TO FRICTION AND WEAR (including losses in manufacturing processes, machines and systems)
It is estimated that ~1/3 of the energy produced in the world is consumed to overcome friction*
Even moderate friction reduction could result in very significant energy conservation
Idea for Meeting the Challenge
MANUFACTURING METHODS THAT ALLOW THE GENERATION OF “ENGINEERED SURFACES” WITH PRESCRIBED TOPOGRAPHIES AND FRICTION PROPERTIES
Traditional friction reduction methods, i.e., polishing, grinding, low friction coatings, lubricants, etc. are limited in their ability to precisely control the behavior of surfaces in contact
Lack of full understanding of the physics of contacting surfaces
Approach
DEVELOP MICRO-TEXTURING PROCESSES IN COMBINATION WITH NON-GEOMETRIC SURFACE MODIFICATION METHODS TO CONTROL FRICTION/WEAR BEHAVIOR
Example: Laser texturing in combination with laser-assisted chemical modification
Roll-forming with rolls with micro-features to achieve high production throughput, etc.
What is the Manufacturing Challenge
NEW HYBRID TEXTURING PROCESSES
FUNDAMENTAL UNDERSTANDING OF ENERGY DISSIPATION IN CONTACING SURFACES
THE SCIENCE OF “SURFACE ENGINEERING”
* Szeri, A. Z., Ed., (1980), Tribology, Friction, Lubrication and Wear, Hemisphere Publishing Corp., McGraw Hill, New York.