A Novel Process for Manufacturing High-Friction Rings with a Closely Defined Coefficient of Static Friction (Relative Standard Deviation 3.5%) for Application in Ship Engine Components

Abstract

In recent years, there has been an increased uptake for surface functionalization through the means of laser surface processing. The constant evolution of low-cost, easily automatable, and highly repeatable nanosecond fibre lasers has significantly aided this. In this paper, we present a laser surface-texturing technique to manufacture a surface with a tailored high static friction coefficient for application within driveshafts of large marine engines. The requirement in this application is not only a high friction coefficient, but a friction coefficient kept within a narrow range. This is obtained by using nanosecond-pulsed fibre lasers to generate a hexagonal pattern of craters on the surface. To provide a suitable friction coefficient, after laser processing the surface was hardened using a chromium-based hardening process, so that the textured surface would embed into its counterpart when the normal force was applied in the engine application. Using the combination of the laser texturing and surface hardening, it is possible to tailor the surface properties to achieve a static friction coefficient of ≥0.7 with ~3–4% relative standard deviation. The laser-textured and hardened parts were installed in driveshafts for ship testing. After successfully performing in 1500 h of operation, it is planned to adopt the solution into production.