An Experimental Study of Friction and Durability of a Thin PTFE Film on Rough Aluminum Substrates

ABSTRACT

Frictional and durability characteristics of 1-µm-thick polytetrafluoroethylene (PTFE) films deposited by hot filament chemical vapor deposition on aluminum substrates were investigated. A universal microtribotester was used to examine the frictional and durability properties using the ball-on-plate and ball-on-disk configurations, respectively. Effects of normal force (2.5, 5, 10, 15 N), sliding speed (0.1, 1, 5 mm/s), and surface roughness of the aluminum substrate (R_a = 0.01, 0.57, 1.28, 2.34 µm) on the coefficient of friction (COF) and the effects of normal force (2.5, 5 N), sliding speed (0.42, 4.19 mm/s), and surface roughness on the durability were investigated. It was shown that the COF of the PTFE-coated interface increases with increasing surface roughness or sliding speed. The COF depends on the normal force to a lesser extent than the other two parameters. The medium-level, O(0.5 µm), roughness of the substrate provides the longest durability, whereas the smoothest or very rough surface provides shorter durability. Analysis of variance (ANOVA) indicates that the surface roughness has the most significant effect on the COF and durability. In the case of a smooth interface, a relationship between COF, sliding speed, and normal force can be predicted. Results indicate an optimal surface roughness for improving durability.

KEYWORDS:

• PTFE
• polymer tribology
• adhesion
• aluminum substrate
• surface roughness

Funding

This work was supported in part by GVD Corporation (Cambridge, MA).