Investigation of the friction coefficient evolution and lubricant breakdown behaviour of AA7075 aluminium alloy forming processes at elevated temperatures

Abstract The lubricant behaviour at elevated temperatures was investigated by conducting pin-on-disc tests between P20 tool steel and AA7075 aluminium alloy. The effects of temperature, initial lubricant volume, contact pressure and sliding speed on the lubricant behaviour (i.e. evolutions of the coefficient of friction (COF) and the breakdown phenomenon) were experimentally studied. The evolutions of COF at elevated temperatures consisted of three distinct stages with different friction mechanisms. The first stage (stage I) occurred with low friction when the boundary lubrication was present. The second stage (stage II) was the transition process in which the COF rapidly increased as the lubricant film thickness decreased to a critical value. In the final plateau stage (stage III), lubricant breakdown occurred and intimate contact at the interface led to high friction values. At the low friction stage (stage I), the value of COF increased with increasing temperature. The increase in temperature, contact pressure and sliding speed as well as the decrease in initial lubricant volume accelerated the lubricant breakdown.