Experimental investigation of junction growth of rough contacts using X-ray computed tomography

The real contact area (RCA) of randomly rough contacts has received a great deal of attention because it correlates strongly with friction, lubrication, sealing, and conductivity. Simulations have revealed that the RCA associated with deterministic normal squeezing loads increases when tangential loads are also applied, in a phenomenon called junction growth. However, experimental investigations of the junction growth of randomly rough contacts are rare. Here, we used X-ray computed tomography (CT) to measure junction growth when two aluminum alloy surfaces were in contact. A high-resolution experimental setup was used to apply loads and observe contact behaviors at a resolution of 4 µm. The RCA and average contact gaps were computed using a three-dimensional (3D) geometric model constructed from gray CT images using the Otsu thresholding method. The results showed that the RCA increased as the normal load increased. The RCA increased by 22.67% after a tangential load was applied (junction growth), and the average gap decreased by 14.01% after a tangential load was applied. Thus, X-ray CT accurately measured the junction growth as a novel quantitative method.