Component bench tests are a crucial part of a tribology assessment experimental programme for most engines and subsystems. This is because they test the components under conditions simulating the operating characteristics of the system. These have become very important as they shed more light into the friction, wear, lubrication and importantly for this study, the tribochemistry of valve train systems. This work outlines the procedure for the development of a single cam rig (SCR) from a 1.25L FORD Zetec (SE) engine. Friction plots were used to validate the data obtained from the newly developed single cam rig with Mn-phosphate coated and polished follower against a cast iron camshaft. The tribofilm formed using normal and mid Sulphated Ash, Phosphorus and Sulphur (SAPS) 5W-30 oils were evaluated and correlated to the friction and wear properties of the tribopair.Raman and FIB-SEM/EDX investigations of the tribochemical films showed that the normal SAPS oil produced patchy, thick (80-100 nm) and well dispersed tribofilm with better wear prevention capabilities. It was observed that Mid SAPS oil had lower wear prevention due to loosely dispersed and thin tribofilms. Absence of tribofilms at the centre of the insert with this oil also suggests that formation and removal processes are an integral part of the wear mechanisms in highly loaded cam follower systems.

In a direct acting valve train configuration, tappet rotation plays a key role in improving lubrication, reducing wear and friction. However, to the best of the authors' knowledge, no studies were found to investigate the rotation of tappet under the effect of different coatings, thicknesses of tappets and formulations with Molybdenum Dialkyl Dithiocarbamate (MoDTC) which has been recently reported to be detrimental to Diamond-Like Carbon (DLC) wear. In this work, a new technique of measuring tappet rotation has been developed. A giant magnetoresistance (GMR) sensor coupled with a split pole ferrite disk magnet was used. The sensor was installed very close to the tappet/bucket while the magnet was mounted into the underside of the tappet. Experiments were performed using standard production steel tappets coated with Mn-phosphate (MnPO4) and diamond-like carbon (DLC) coatings. In general, results showed that the tappet rotation is strongly dependant on oil formulation, clearance, speed/temperature, and surface roughness of the coating. MoDTC promoted the rotation of the tappet under both coatings. In addition, DLC inserts showed an increase in tappet rotation as compared to MnPO4 inserts. Nevertheless, regardless of the type of coating, the thickest tappets showed the highest rotation.

This paper examines the effect of tappet insert clearance on the tribological and tribochemical performance of the camlobe/follower tribopair when lubricated in a fully-formulated oil containing 1 wt% of Molybdenum Dialkyl Dithiocarbamate (MoDTC). Tests were performed on a Single Cam Rig (SCR), taken from 1.25l FORD Zetec (SE) engine. White Light Interferometry and Talysurf contact profilometry were used to characterise the wear scar on the tappet inserts and camlobes respectively. In addition, Scanning Electron Microscopy (SEM) was used on both (i.e. camlobes and tappet inserts) for wear mechanisms assessment as well as to access the durability of coatings used on tappet inserts. Energy-Dispersive X-ray (EDX) and Raman spectroscopy analyses were also used to understand the tribochemical interactions between oil additives and the cam/follower interface. Results show that the chemistry of the tribofilm derived on camlobes and tappet inserts vary as a function of tappet insert clearance and cam profile. Also, regardless of the type of coating, the smaller clearance of tappet inserts exhibited higher friction and wear. Therefore, based on this work, the use of the thicker tappet insert would be inadvisable as this possibly can cause higher fuel consumption and inefficient performance of the intake/exhaust valves of the engine.