A Novel Testing Methodology to Predict the Endurance of Ball Joints in Absence of Lubrication at High Temperature

The enhancement of the operational flexibility of axial expanders can be obtained through the implementation of Nozzle Guide Vane (NGV). This design architecture includes moving parts typically sustained by ball joints, whose wear behavior might be important to define the maintenance interval of the expander and define its operational availability. This is especially true when considering challenging loading and temperature conditions. Usually, tribological tests are performed by pin-on disk or similar test methods. However, these techniques neglect important factors as actual sliding zone and contact morphology, which can be fundamental for ball joints. This work deals with the design of an innovative experimental test procedure for the characterization of the tribological behavior of ball joints considering the actual operating conditions of a NGV at 500°C. The core of the methodology is a customized test bench specifically designed to investigate actual commercial ball joint in field conditions. Details on the design phase and on the commissioning of the experimental set-up are given. The results of the experimental campaign performed on this novel test bench are presented: the chosen test matrix explores a wide spectrum of load and sliding speed. Specimen pre-load and working velocity have been scaled-up to achieve viable testing duration. The test bench was employed on three different kinds of commercial ball joints for high-temperature applications in absence of lubrication. Measurement of diametral clearance and friction in worn conditions were also performed. The results discussion allowed to choose the most suitable solution for a specific design targeting 50000 working hours.