Abstract:
To focus on the in-service performance of three types of solid lubricant coatings on the surface of aero-engine fuel pump thrust bearings in aviation kerosene under simulated actual working conditions, to clarify the intrinsic mechanism of frequent flake peeling during their use, and to select a coating with superior comprehensive performance. This study also aims to provide guidance for the future development of protective coatings with better lubrication, wear resistance, and anti-cavitation erosion functions. Using an MMW-1 vertical universal tribo-wear testing machine and an ultrasonic vibration cavitation erosion testing machine, the tribological and cavitation erosion properties of three bonded solid lubricating coatings mainly based on polyamide- imide (PAI) as a binder resin, MoS
2/ graphite-based bonded solid lubricating coating, MoS
2-based bonded solid lubricating coating, and graphite-based bonded solid lubricating coating, in RP-3 aviation kerosene were comparatively studied. To simulate actual working conditions closely, the gear material 2Cr3WMoV was selected as the counterpart material for tribological tests. Based on optical microscopy (OM), three-dimensional optical profilometry, and scanning electron microscopy (SEM), the original surface of the coatings and the surface morphology after friction and cavitation erosion were analyzed. The phase composition of the coatings before and after friction were compared using a high-resolution X-ray diffractometer (XRD). Raman spectroscopy was used to characterize the components of the friction transfer films and the cavitation erosion peeling debris of the coatings, and the protection and failure mechanisms of the coatings were discussed. The results showed that in the RP-3 medium, with graphite as a lubricant, the friction coefficient of graphite-based bonded solid lubricating coating was as low as 0.083, and the wear rate was 1.5×10
−6 mm
3/(N·m), exhibiting the best tribological performance. The original solid lubricant particles embedded in the resin structure in the microstructure of MoS
2/graphite-based bonded solid lubricating coating and graphite-based bonded solid lubricating coating disappeared, and a layered structure similar to scales appeared. There were no phase changes in the wear scar areas of the three coatings before and after friction, maintaining good tribological chemical stability. During the friction transfer process, the intensity ratio of D peak to G peak of graphite significantly increased, forming a graphite-like structure. The transfer films formed on the surface of the counterpart material was beneficial for further reducing the friction coefficient. The three coatings were subjected to dual attacks from cavitation load and cavitation heat in aviation kerosene, resulting in poor anti-cavitation erosion performance, showing the characteristic of "filler particles falling off first accelerating flake peeling" of the coating, and a "melt bead" structure not present in the original structure of the coating appears on the coating surface. Due to the poor load-bearing capacity and large particle size of MoS
2, the degree of cavitation erosion peeling was the most serious, resulting the MoS
2/ graphite-based bonded solid lubricating coating to fall off with an area of up to 95.83% after 10 hours of accelerated cavitation erosion. The anti- cavitation erosion performance of graphite-based bonded solid lubricating coating was better, with a coating fall-off area of 84.73%. The Raman spectroscopy results of the fallen debris from the three coatings indicated that cavitation erosion has little effect on the layered structure and phase composition of graphite and MoS
2. In summary, we believe that the comprehensive operational performance of graphite-based bonded solid lubricating coating is more suitable for promoting the use of thrust bearing surfaces at this stage.