michael lubwama wil workshop 2012 - welcome to...
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Tribological behaviour of DLC and Si-DLC films deposited on nitrile rubber for
piston seals
Michael LubwamaSupervisors: Dr. B. Corcoran, Mr. K. Sayers, Dr. J.B. Kirabira, Dr. A. Sebbit
Sustainable handpump technologies
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TitleOutline
Brief background
Aims and objectives
Methodology
Results
Conclusions
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TitleWorld Water Situation
330
222
151
83
3821 17 13 54
Sub-Saharan Africa
Southern Asia
Eastern Asia
South Eastern Asia
Latin America & Caribbean
Western Asia
Commonwealth of Independent States
Northern Africa
Oceania
Developed Regions
About 1 billion people do not have access to safe water; with sub-Saharan Africaaccounting for about 33 % [JMP Report, 2010]. 3
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TitleWater Situation – Makondo Parish
Less thanone-third of
thehandpumps
werefunctional
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TitleHandpump Component Repairs
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TitleDry and Wet Sliding
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TitleWear Mechanisms
_ _ _ _wear total abrasive wear adhesive wear fatigue wearV V V V 7
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TitleFunctional Sustainability
• Handpump reliability is defined asmechanical availability [Reynolds, 1992]
• A trade off has to be made betweenreliability and maintainability
• Maximum pump functionality; minimalnumber of maintenance interventions
• Increased pump availability through longeroperation time of the seal [Aspegren et al.1987]
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TitleSurface Engineering Approach
The systems in place are not altered:
1. Labour
2. Training
3. Design, development and manufacturing
4. Supply chain systems
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TitleResearch Objectives
• To quantify field and user operating conditionsrelating directly and indirectly to piston seal failure
• To deposit DLC and Si-DLC films, with and withoutSi-C interlayers onto NBR substrates and actualpiston seals using an industrial closed fieldunbalanced magnetron sputtering ion plating(CFUBMSIP) rig.
• To characterise the structural and mechanicalproperties; and tribological behaviour of DLC andSi-DLC films, with and without Si-C interlayersdeposited on NBR substrates
• To determine the wear mechanisms of actualpiston seals coated with DLC and Si-DLC films,with and without Si-C interlayers, using a purposelydesigned and developed test rig.
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TitleCoating Process Design
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TitleCFUBMSIP
• Field lines “closed” with anothermagnetron
• Plasma confined aroundsubstrates
• Electrons and ion loss to chamberwalls minimised
• Possibility to produce lowtemperature coatings
• Dense, non-columnar , adherentcoatings
• Coating deposition is carried outusing a high density of lowenergy bombarding ions
• Teer Coatings UK (Miba coatinggroup)
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TitleCFUBMSIP Sputtering Rig and InteriorSet-up
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TitleCoating Deposition Parameters
Coating Type Ion Cleanprocess
Ar(sccm)
C4H10
(sccm)C(A)
Si(A)
Bias(V)
Coating time(min)
DLC 200V for 10min
12 8 2 0 30 60
Si-DLC 200V for 10min
12 8 2 0.5 30 60
Si-DLC with Si-C interlayer
200V for 10min
12 8 2 0.5 30 35 for Si-C/40 for DLC
DLC with Si-Cinterlayer
200V for 10min
12 8 2 0 30 35 for Si-C/40 for DLC
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TitleRaman Spectra
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TitleSurface Morphology
DLC Si-DLC
DLC with Si-C Si-DLC with Si-C
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TitleCoefficient of Friction – Dry Sliding, 1 N
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TitleWear Analysis
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TitlePiston Seal Wear Test Rig
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TitlePiston seal testing - context
• Average number of strokes to fill 20 l container= 115 strokes
• Test rig set up to fill a 20 l container in 113strokes
• Water delivered during one half of stroke = 57mm in test rig design
• For 100000 strokes (24 hour testing regime),17768 l delivered
• This test period covers 1776 10 l containers
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TitleCoated Piston Seals Before WearTesting (side)
DLCSi-DLC
DLC with Si-C
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TitleCoated Piston Seals After Wear Testing
DLC
DLC
Si-DLC
Si-DLC
DLC with Si-C
DLC with Si-C
Top
Lower
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TitleConclusion
• DLC and Si-DLC films with and without Si-C interlayers were deposited onto nitrilerubber and actual piston seals usingCFUBMSIP.
• This Surface Engineering approach offersa method for reducing the wear rate ofpiston seals
• Various characterisation techniques havebeen successfully applied
• Wear testing on actual coated piston sealson-going
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TitleAcknowledgement
• Water is Life Project
• Irish Aid
• HEA
• Dublin City University
• Makerere University
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TitlePublications
1. M. Lubwama, K. A. McDonnell, J. B. Kirabira, A. Sebbit, K. Sayers, D. Dowling, B. Corcoran, Characteristicsand Tribological Performance of DLC and Si-DLC Films Deposited on Nitrile Rubber, Surf. Coat. Technol.206 (2012) 4585-4593
2. M. Lubwama, B. Corcoran, K. Sayers, J. B. Kirabira, A. Sebbit, K. A. McDonnell, D. Dowling, Adhesion andComposite Micro-hardness of DLC and Si-DLC films Deposited on Nitrile Rubber, Surf. Coat. Technol. 206(2012) 4881-4886
3. M. Lubwama, B. Corcoran, K. Sayers, J. B. Kirabira, A. Sebbit, K. A. McDonnell, D. Dowling, Role of Si-CInterlayer on the Properties of DLC and Si-DLC Films Deposited on Nitrile Rubber, under review in ThinSolid Films Journal
4. M. Lubwama, B. Corcoran, K.A. McDonnell, D. Dowling, J.B. Kirabira, A. Sebbit, K. Sayers, Flexibility andtribological behaviour of DLC and Si-DLC films deposited on nitrile rubber, under review in Surface andCoatings Technology Journal
5. M. Lubwama, B. Corcoran, K. Sayers, J. B. Kirabira, A. Sebbit, Closed Field Unbalanced MagnetronSputtering Ion Plating of DLC and Si-DLC Films onto Nitrile Rubber, Proceedings of the 29th InternationalManufacturer’s Conference, Belfast, UK
6. M. Lubwama, B. Corcoran, K. Sayers, J. B. Kirabira, A. Sebbit, K. A. McDonnell, D. Dowling, Role of Si-CInterlayer on the Properties of DLC and Si-DLC Films Deposited on Nitrile Rubber, Proceedings of the 15th
International Conference on Advances in Manufacturing and Processing Technologies Conference,Wollongong, Australia, 23rd to 26th September, 2012.
7. M. Lubwama, K. Sayers, J. B. Kirabira, B. Corcoran, Wear Mechanisms of Piston Seals for reciprocatinghandpumps for rural water supply, Proceedings of the Second international Conference on Advances inEngineering and Technology, Macmillan Africa, pp. 612 – 618
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TitleQuestions
Thank You
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