Fuel and water contents are inevitable in automotive engine oils. This study intends to investigate the impact of the addition of gasoline (3–20%) and water (1%) on the lubricating performance of synthetic base oil (PAO), with or without an anti-wear additive (ZDDP), for a steel-cast iron contact. Fuel-added PAO showed an increase in the load carrying capacity. Oil electrical conductivity and total acid number (TAN) measurements showed slightly increased conductivity and marginally increased acidity at a higher fuel concentration. In contrast, an increased wear rate, proportional to the fuel concentration, was observed in a prolonged test with constant-loading. Results suggested that the fuel addition is a double-edged sword: reducing the scuffing risk by providing stronger surface adsorption and increasing the sliding wear rate by bringing down the oil viscosity. The PAO-water blend formed an emulsion and resulted in a significantly increased load-carrying capacity, again likely due to the higher polarity and possibly acidity. For the ZDDP-containing PAO, the addition of 1% water and 3% fuel generated 24% and 52% higher wear. The phosphate polymerization level was reduced on the worn surfaces by the introduction of water but the thickness of ZDDP tribofilm was not significantly affected.

Friction stir forming (FSF) is a new environmentally friendly manufacturing process for lap joining of dissimilar materials. Fundamentally, this process is based on frictionally heating and mechanically stirring work material of the top piece in a plasticized state to form a mechanical interlocking joint within the bottom material. In this research, the significant process parameters were identified and optimized for Al 6014 alloy and mild steel using a design of experiments (DOE) methodology. The overall joint structure and grain microstructure were mapped as the FSF process progressed and the aluminum work material deformed through different stages. It was found that the work material within the joint exhibited two layers, thermomechanical affected zone, which formed due to the contact pressure and angular momentum of the tool, and heat affected formation zone, which was composed of work material formed through the hole in the steel sheet and into the anvil cavity. Two different geometries of anvil design were employed to investigate geometrical effects during FSF of the aluminum. It was found that the direction and amount of work material deformation under the tool varies from the center to the shoulder.

Coolant flow-induced relative motions between certain structural components in the cores of lightwater nuclear reactor cores, a phenomenon called Grid-To-Rod Fretting (GTRF), can result in progressive wear damage. Wear-through of the cladding on fuel rods can introduce radioactive species into the coolant loop. Such an event is termed a “leaker” and may cause premature and expensive reactor shut-down. GTRF results in wear scars of various sizes, shapes, and depths on the sides of the fuel rod cladding. Fretting damage may also occur on the springs and dimples that hold the fuel rods in place, resulting in the formation of gaps. Due to variability in the operating conditions of the reactor (burn-up rates and operating campaigns) and the associated variable cladding surface oxide film growth and removal rates, the wear coefficient is unlikely to remain constant over time. Therefore, constant wear rate models do not accurately account for transients in the operating conditions.

Coolant flow-induced relative motions between structural components in the cores of lightwater nuclear reactor cores, a phenomenon called Grid-To-Rod Fretting (GTRF), can result in progressive wear damage. Wear-through of the cladding on fuel rods can introduce radioactive species into the coolant loop. Such an event is termed a “leaker” and may cause premature and expensive reactor shut-down. GTRF results in wear scars of various sizes, shapes, and depths on the sides of the fuel rod cladding. Fretting damage may also occur on the springs and dimples that hold the fuel rods in place, resulting in the formation of gaps. Due to variability in the operating conditions of the reactor (burn-up rates and operating campaigns) and the associated variable cladding surface oxide film growth and removal rates, the wear coefficient is unlikely to remain constant over time. Therefore, constant wear rate models do not accurately account for transients in the operating conditions.