Thermal Wear Sensing System: Proof of the Concept

A technique for wear sensing using a sacrificial layer with specific material properties has been developed successfully. This is achieved by recording the temperature evolution underneath the sacrificial organic layer during sliding tests, and by correlating the recorded temperature with a wear depth. Finite element modeling was used to calculate the contact temperature which spreads through the sacrificial layer under different sliding test conditions. Numerical simulation was used to determine the optimal parameters for the best correlation between temperature and wear depth. These parameters were used to select the appropriate sacrificial layer for wear sensing. Thus, an epoxy layer was implemented and experimental measurements were carried out to check the correlation between the measured temperature underneath the epoxy layer and wear depth. It was found that a low thermal conductivity of the sacrificial layer of less than 1 W/m K and a relative high thermal conductivity of the substrate, namely more than 4 W/m K are the optimal parameters for our thermal wear sensing system. The thickness of the sacrificial layer is also a crucial parameter and has to be taken into account when designing such a sensing system.