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Abrasive wear, high loads, coatings/material selection

Abrasive wear, high loads, coatings/material selection

Abrasive wear, high loads, coatings/material selection

(OP)
I currently have an issue dealing with two cam plates separated by three ball bearings. We use grease as a lubricant however we are interested in using a coating lubricant. The total pressure between the plates is around 100,000psi. Xylan was tried, and was impressive,however did not quite meet the requirements we are looking for. Erdemir is another coating which we are looking into. Another possible solution to this, however, is changing the materials. We have tried carbide balls, chrome balls, ceramic balls, titanium balls, nickel coated plates and many other various possible fixes. I am wondering if perhaps anyone has a recommendation on this matter; a coating or different material combination that will withstand adhesive wear under extremely high loads. The current cam plates are D2 steel. The balls are 52100. The best possible solution involves only changing the ball bearings. The material selection for the cam plates is not very flexible.  

RE: Abrasive wear, high loads, coatings/material selection

Does the wear occur on the plates?  What is the hardness for the plates?  Ceramic balls with a lubricated, hard wear surface should produce the best results.  I would investigate a hard coating on the D2-- diamond like coatings (DLC) or something that will not reduce the hardness of the D2 due to high processing temperature.  What was the exact problem with the Xylan?  Which grade of Xylan?  Try a lubricant based on MoS2 instead of PTFE/PFA if that was the grade used previously.  Is temperature a concern?

RE: Abrasive wear, high loads, coatings/material selection

(OP)
Yes, the wear does occur on the plates. The hardness for the plates is around 58 Rockwell C. The temperature ranges from 0F to 200F degrees-
Xylan proved to be very effective, (better than anything else we've tried thus far), however it still can not withstand the 100,000psi load for over 100,000 cycles. We're looking for about a quarter million-
MoS2 has been tried with zinc coated plates and only got to around 20,000 cycles. AlSi balls (ceramic) only got us to around 4300 cycles due to ball breakdown/fracture and severe wear on the track surface.
I haven't looked into DLC coatings as I am unfamiliar with them, however I will be sure to-
thanks in advance

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