Tribological component testing and system analysis

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R&D services for tribological component testing and system analysis

Why should my company work with Fraunhofer IWM on tribological component testing and system analysis?

Tribological component testing and system analysis publications

Conservation of resources and energy efficiency make friction and wear both competitive and sustainable factors. An optimum materials technology strategy requires precise knowledge and understanding of the friction partners, the lubricants used and the stresses on the tribological system. This is where we come in: we use experiments, simulations and analytics to create a sound understanding of the mechanisms in the friction gaps and the resulting coefficients of friction and wear rates under operating conditions. Building on this, our projects aim to develop sustainable, robust and controllable tribological systems. A basic prerequisite for the evaluation and improvement of tribological systems is a system analysis in which the interacting materials and stresses are systematically described. Our aim is to effectively protect components from wear under complex and challenging conditions and to improve the energy and resource efficiency of technical systems.

Fields of application and challenges

High temperature tribology

Whether in drives, manufacturing processes or power generation, friction contacts must reliably function everywhere, even with insufficient lubrication. High temperatures often limit the performance of friction-loaded systems. Understanding and being able to influence thermal effects in tribological systems is a prerequisite to optimizing tribological behavior.

Hydrogen tribology

The use of hydrogen-containing gases in combustion engines is increasing. More and more energy is being generated in power plants through H2 combustion. Bearings and seals in pumps and compressors for transporting hydrogen are subject to new stresses. Mastering tribological systems in contact with hydrogen is one of the keys to achieving the success of the energy transition.

Electrotribology

Electrical voltages in bearings, seals or gearboxes in wind turbines or electric mobility can affect the lubricants used, cause damage and reduce the service life of the systems. On the other hand, the friction properties can be controlled by electrical voltages. We identify, control and utilize electrical effects in tribological systems.

Sustainable lubricants

Water-based lubricants are environmentally friendly and effective. After all, water is less viscous than oil. The disadvantages of water are the limited application temperature range and corrosion. The latter was previously the co-criterion. We develop solutions to make water suitable for lubricants with additives and to prevent corrosion.

Polymer tribology

The advantages of lubricated plastics for both slide and roller bearings are immense, including noise damping, elasticity and cost-effectiveness. However, the tribology of polymers is complex: lubricants can lead to unexpected friction and wear behavior while elastomers exhibit higher wear rates in an aggressive atmosphere. We create the basis for reliable polymer tribosystems.

Biomedical Materials

Hip joint prostheses, bone cements and dental implants have to withstand millions of load cycles. Bone cements should not exhibit critical creep deformation under load. A micro bone screw should be screwed in quickly and "grip" in a defined manner. The combination of reliable mechanics and tribology is crucial for safe use.

High-performance ceramics

Ceramic materials are superior to metallic materials or polymers in many challenging applications. However, it must be ensured that the component loads occurring during use are within defined limits. To evaluate the use of high-performance ceramics, we simulate complex and extreme stresses in the laboratory and determine the critical success factors.

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R&D services for tribological component testing and system analysis

Tribological system analysis

System analyses can be carried out in accordance with the recommendations of the Society for Tribology or individually adapted. This analysis forms the basis for the description, evaluation and optimization of tribological systems.

Tribological standard tests

For the certification of your materials and components, you need friction and wear characteristics in accordance with a specific guideline. We characterize and evaluate single-sided and oscillating sliding stresses as well as rolling and abrasive stresses under the influence of media and temperature.

Tribological component testing

We have specific test benches for many components in order to simulate practical conditions and test optimization strategies. Examples include test rigs for gas engine valves, radial bearings, roller bearings, axial plain bearings and mechanical seals as well as secondary seals. We develop test set-ups for your specific application to clarify the friction and wear mechanisms

Damage analyses

In order to determine the causes of damage to components, we simulate the operational loads and investigate various influencing factors in model tests. This makes it possible to trace typical failure patterns in complex load scenarios. A specific component test in combination with comprehensive material analysis leads to the targeted clarification of your damage case and to measures for sustainable prevention.

Development of testing techniques

Tailor-made solutions require tailor-made testing techniques. We simulate customer-specific load conditions on a laboratory scale and design economical and effective test setups.

Material analysis

We use comprehensive material analysis methods to investigate the effects of tribological stresses on the components of a tribological system. This enables us to measure and evaluate wear mechanisms, microstructural damage, lubricant degradation and corrosion.

Material and component simulation

To overcome tribological challenges, we simulate wear, heating and load in materials and components. We also use numerical simulations to improve the functionality of materials, components and tribological systems in a hydrogen atmosphere and under hydrogen load.

Development of tribosystems and material substitution

Critical raw materials that need to be replaced are used in many bearings, sliding pairs and lubricants. We design substitution strategies and identify suitable substitute materials. We take a holistic approach to evaluating feasibility, manufacturability and functionality.

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Why should my company work with Fraunhofer IWM on tribological component testing and system analysis?

With our expertise in materials science, we bridge the gap between the behavior and properties of materials and the functionality, efficiency, safety and durability of tribological systems made from them.

We provide the materials knowledge, methods and solution options that enable decision-makers in companies to make reliable material technology decisions regarding the performance, cost-effectiveness and longevity of their products and systems.

We enjoy working together with experts from companies to develop material technology challenges and translating them into an economical and effective research project.

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