Study of tribological properties of bulk nanostructured aluminum and copper samples applicable in automotive bearing application

Using lightweight systems and friction reduction approaches are two main contributors towards modern and efficient powertrains in the automotive industry. New materials and processes are required to achieve the demanding and ever-increasing performance requirement of automotive systems. Nanostructure induced by Severe Plastic Deformation (SPD) methods involves bimodal microstructures and hence, shows exceptional mechanical characteristics which can be exploited for automotive application. Through this study, pure copper, and aluminum alloy samples (series7000) were processed to attain bulk nanostructured samples using a Single Step High Pressure Torsion technique with appropriate dimensions applicable as the rolling elements of automotive bearings. The induced nanostructures resulted micro hardness and frictional characteristics of the bulk samples were assessed using transmission electron (TEM) and atomic force (AFM) microscopies as well as microhardness evaluations. The results revealed that a fully refined nanostructured samples were achieved with 90% increase in the hardness at the outer diameter of the sample. The AFM measurements indicated that the friction coefficient of nanostructured copper and aluminum samples were ~25% and ~45% less than that of both the unprocessed samples, respectively. Characteristics of treated samples suggest that these processes can be potentially used in demanding conditions of rolling element bearings with reduced weight and frictional losses.