Surface Fatigue Behaviour of a WC/aC:H Thin-Film and the Tribochemical Impact of Zinc Dialkyldithiophosphate

In wind turbine gearboxes, (near-)surface initiated fatigue is attributed to be the primary failure mechanism. In this work, the surface fatigue of a hydrogenated tungsten carbide/amorphous carbon (WC/aC:H) thin-film was tested under severe cyclic tribo-contact using PolyAlphaOlefin (PAO) and PAO + Zinc DialkylDithioPhosphate (ZDDP) lubricants. The film was characterised in terms of its structure and chemistry using X-ray diffraction, analytical Transmission Electron Microscopy (TEM) including Electron Energy Loss Spectroscopy (EELS), as well as X-ray Photoelectron Spectroscopy (XPS). The multilayer carbon thin-film exhibited promising surface fatigue performance showing a slight change in the hybridization state of the aC:H matrix. Dehydrogenation of the thin-film and subsequent transformation of cleaved C-H bonds to non planar sp2 carbon rings were inferred from EELS and XPS results. Whilst tribo-induced changes to the aC:H matrix were not influenced by a nanometer-thick ZDDP reaction-film, the rate of oxidation of WC and its oxidation state were affected. Whilst accelerating surface fatigue on a steel surface, the ZDDP-tribofilm protected the WC/aC:H film from surface fatigue. In contrast to the formation of polyphosphates from ZDDP molecules on steel surfaces, it appeared that on the WC/aC:H thin film surface ZDDP molecules decompose to ZnO suppressing the oxidative degradation of WC.