How do you prevent fretting wear and corrosion in sliding contacts?

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Fretting wear and corrosion are common problems in sliding contacts, such as bearings, gears, and electrical connectors. They occur when small oscillatory motions cause friction and damage the surface layers of the materials, exposing them to oxidation and chemical reactions. Fretting can reduce the performance, reliability, and lifespan of your components and systems, leading to costly failures and downtime. How do you prevent fretting wear and corrosion in sliding contacts? Here are some strategies you can apply to reduce the risk and severity of fretting.

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Hamilton Feijó

Economist | 100X ?? Linkedin Top Voice | Innovation and Strategy Specialist | Business Manager | Corporate Social…
Ruta Barve

Entrepreneur Director | Materials Science Engineer | Advisor to Startups
ANURAG SAHU

Doctoral Researcher in Metallurgical and Materials Engg. (IIT Madras) | Additive Manufacturing (at IIT Palakkad) |…

1 Choose compatible materials

One of the factors that influence fretting wear and corrosion is the material compatibility of the sliding surfaces. You want to avoid materials that have a high tendency to adhere, deform, or transfer under friction, or that have different electrochemical potentials, which can accelerate corrosion. You can use material selection charts, tribological tests, or corrosion tables to compare and select the best materials for your application. For example, you can choose materials with low friction coefficients, high hardness, or similar galvanic properties.

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Ruta Barve

Entrepreneur Director | Materials Science Engineer | Advisor to Startups
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In case you need to consider same material grade for mating parts in sliding contact then one may consider differing the hardness of the two parts which can be atleast 5 points (HRc) apart.

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Muhammad Muteeb Butt

Additive Manufacturing, Root Cause Failure Analysis, Replica Metallography, Damage Mechanism Assessment, Material Testing, Remaining Life Assessment, Product Development
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The mating materials should be chemically different to avoid mutual solubility. This prevents adhesion and cold welding, which can lead to increased wear and potential failure of the components. The hardness of the materials should be balanced. There should not be a significant difference in hardness, as this can cause one surface to wear down the other, leading to abrasive wear. Choosing materials with appropriate hardness levels ensures durability and longevity of the sliding contacts, reducing the risk of excessive wear.

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2 Apply protective coatings

Another way to prevent fretting wear and corrosion is to apply protective coatings on the sliding surfaces. Coatings can provide a barrier against friction, oxidation, and chemical attack, as well as improve the surface properties and appearance of the materials. You can choose from various types of coatings, such as metallic, ceramic, polymer, or composite coatings, depending on your requirements and budget. You can also use different coating methods, such as electroplating, spraying, painting, or dipping, to achieve the desired thickness and uniformity of the coating.

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3 Use lubricants and additives

A third strategy to prevent fretting wear and corrosion is to use lubricants and additives in the sliding contacts. Lubricants can reduce friction, heat, and wear by forming a thin film between the sliding surfaces, as well as prevent corrosion by displacing moisture and contaminants. Additives can enhance the performance and durability of the lubricants by providing anti-wear, anti-corrosion, anti-oxidation, or anti-fretting properties. You can select the appropriate lubricant and additive based on the operating conditions, such as temperature, pressure, speed, and load, of your sliding contacts.

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Hamilton Feijó

Economist | 100X ?? Linkedin Top Voice | Innovation and Strategy Specialist | Business Manager | Corporate Social Responsibility |
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The use of appropriate lubricants and additives can significantly reduce wear and corrosion on sliding contacts. For example, in car engines, the application of high-quality lubricating oils can protect the contact surfaces from premature wear, extending the life of the components.

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4 Control the environment and load

A fourth strategy to prevent fretting wear and corrosion is to control the environment and load of the sliding contacts. You want to avoid exposing the sliding surfaces to harsh or variable conditions, such as high humidity, temperature, salinity, acidity, or vibration, that can aggravate fretting and corrosion. You can also reduce the load and frequency of the sliding motions, or increase the amplitude and range of the motions, to minimize the stress and damage on the surfaces. You can use environmental chambers, sensors, dampers, or springs to regulate and monitor the environment and load of your sliding contacts.

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Ruta Barve

Entrepreneur Director | Materials Science Engineer | Advisor to Startups
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Galvanic corrosion can’t set in unless two dissimilar material grades are in electrical contact with each other in presence of an electrolyte. Usually water or condensed moisture acts as the electrolyte. Hence it is equally important to control the environment in which two components in sliding contact are operating.

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5 Perform regular maintenance and inspection

A fifth and final strategy to prevent fretting wear and corrosion is to perform regular maintenance and inspection of your sliding contacts. You want to keep your sliding surfaces clean, dry, and free of debris, dust, or corrosion products that can interfere with the sliding function and cause further wear and corrosion. You also want to check your sliding surfaces for signs of fretting, such as wear marks, cracks, discoloration, or noise, and replace or repair them if necessary. You can use cleaning agents, brushes, wipes, or compressed air to clean your sliding surfaces, and use visual, acoustic, or electrical methods to inspect them.

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ANURAG SAHU

Doctoral Researcher in Metallurgical and Materials Engg. (IIT Madras) | Additive Manufacturing (at IIT Palakkad) | Welding | Mechanical Testing | Tribology
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Fretting wear is undesirable as well as unstoppable wherever two surfaces make contact due to the dynamics of the whole system (eg. vibration). So, prior knowledge regarding their wear rate will give the idea of the extent of damage with wear volume by periodic inspections.Also, high contact pressure between the two surfaces (due to design fault) might cause subsurface crack which are impossible to detect and lead to catastrophic failure. In such cases, rather than further hard coating: prevention is better than cure.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Ravir Bhatnagar

Innovative and Results Driven Materials/Metallurgical Engineering Professional
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Proper packaging and handling of sheet steel (blanks and coils) is critical as well as the temperature and humidity levels should be monitored.

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Cyrus K. Davies SR ( ABDAVIES )

Ex - IIAF, Navel Aviator (1977-1979) stationed at NAS Pensacola, FL; Semiretired from semiconductor industry; Self Employed Independent Contractor
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SKF Anti-Fretting Agent LGAF 3E may be used which’s essentially a lubricant between surfaces if there’s contact spaces between metals…

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How do you prevent fretting wear and corrosion in sliding contacts?

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1 Choose compatible materials

2 Apply protective coatings

3 Use lubricants and additives

4 Control the environment and load

5 Perform regular maintenance and inspection

6 Here’s what else to consider

Failure Analysis

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