Tribofilm development
Stepped pyramids (ziggurats) were constructed using continuous fluid cell experiments lasting several days. During this time the scanned area was increased stepwise so that the previously developed tribofilm was included within the new scan region and thus continued to develop under the applied sliding load. Intermittently, the structure was imaged in contact mode with a non-perturbative load. The number of tribo-cycles selected for each step was limited due to operational (the fluid meniscus occasionally collapsed at unpredictable moments) and time constraints. Thus, scans were set running as early as possible in a morning and the scan areas changed 3–6 hours later (prior to evening departure) and again 18–19 hours later (after morning arrival), etc. In this paper we describe the production and analysis of a 4-stage stepped tribofilm which is typical of those that can be formed using this procedure.
An initial tribofilm was formed by sliding the AFM at a load corresponding to a tip pressure of ~ 5.5 GPa over an area of 2 x 2 µm for 1000 cycles at 40 Hz. After the scan had finished, the area was increased to 4 x 4 µm and a 3D topographic image was obtained using imaging parameters, Fig. 2(a). Next, the AFM tip load and scan rate were returned to tribofilm formation conditions over the same 4 x 4 µm region (i.e. inclusive of the initial 2 x 2 µm area of stage 1 growth) for a further 10,500 cycles. The film was then revealed under imaging conditions over a larger 8 x 8 µm area, Fig. 2(b). Repeating the same process, the imaged 8 x 8 µm area became the locus for formation of the third tribofilm layer for an additional 3000 cycles. Afterwards imaging of a larger 20 x 20 µm area reveals a stepped pyramid (ziggurat) morphology, Fig. 2(c). Finally, after an additional 10,000 cycles, the completed tribofilm was visualised over an area of 40 x 40 µm, Fig. 2(d).

Table 1: XPS elemental analyses and analytical ratios for Zn2p, S2p and P2p over increasing areas of the early tribofilm
Analytical area
|
Tribofilm area
|
P2p
|
S2p
|
Zn2p
|
Zn/P
|
Zn/S
|
P/S
|
700 x 300 μm
|
0.2%
|
0.78%
|
1.83%
|
1.59%
|
2.04
|
0.87
|
0.43
|
55 x 55 μm
|
13%
|
0.82%
|
1.75%
|
1.42%
|
1.72
|
0.81
|
0.47
|
27 x 27 μm
|
54%
|
0.93%
|
1.35%
|
1.14%
|
1.23
|
0.84
|
0.69
|
Extrapolated
|
100%
|
1.05%
|
0.95%
|
0.78%
|
0.74
|
0.82
|
1.11
|
Analytical microscopy
The tribofilm initially generated after 1000 cycles over 4 µm2 appears rough with peak film thickness around 30 nm. Expanding the area to 16 µm2, and after a total of 11,500 cycles, the tribofilm has grown into a relatively homogenous layer around 100 nm in total thickness. At this stage there is no evident separation between the first and second growth stages although the layer has been smeared in the direction of the AFM tip travel (right-to-left). After a further 3,000 cycles over 64 µm2 (14,500 in all) a smooth shelf has clearly developed with thickness around 16 nm and a peak thickness of 105 nm. Finally, an additional 10,000 cycles (now totalling 24,500) over 400 µm2 results in the formation of a second shelf of thickness around 20 nm and a total thickness of 130 nm. We note that the maximum thickness of the tribofilm steadily increased at each stage showing that equilibrium between film removal and regeneration had not yet been reached. The layer thicknesses were determined from the 2D topographic cross-sections shown in Fig. 3.
Figure 4(a) shows an optical microscope image of the 20 x 20 µm multi-layer tribofilm structure and Fig. 4(b) the corresponding secondary electron image. In both cases the different layers can easily be distinguished. Figures 4(c) to (h) show energy dispersive x-ray spectroscopy (EDS) elemental maps where attenuation of the silicon signal, due to its relatively low energy X-ray (1.74 keV), is a proxy indicator for the tribofilm thickness. In contrast the zinc, phosphorus, sulfur and oxygen signals increase in line with tribofilm thickness. Finally, the EDS map for iron is relatively homogeneous across the tribofilm region due its more energetic X-ray (7.11 keV) that can escape from greater depth.
XPS surface analysis
The ziggurat tribofilm consists of 2 merged layers (4 x 4 µm) with a 3rd layer (8 x 8 µm) and a 4th layer (20 x 20 µm). Consequently the 4th layer forms 86% while the 3rd and 4th layers together form 96% of the total tribofilm area. Thus, XPS analysis that extends beyond the confines of the film will be dominated by contributions from the 4th and 3rd layers which represent tribofilm compositions at an early stage of film growth.
Figure 5 presents high resolution XPS spectra for the elements of interest (Zn2p, S2p and P2p) in the tribofilm obtained by sampling three areas centred on the tribofilm. For the largest sampling area, 700 x 300 µm, the measurement is dominated by the thermo-film on the surrounding substrate. However, spectra recorded from 55 x 55 µm and 27 x 27 µm include increasing contributions from the tribofilm. The elemental composition within each of the three areas is presented in Table 2 and have been linearly extrapolated to estimate the composition of the early tribofilm. The analytical peaks for Zn 2p, S 2p and P 2p appear at the same binding energies, with differences in intensity reflected changes in the local chemical composition. As the analysis area shrinks from the thermo-film onto the tribofilm, the zinc to sulfur remains approximately constant, the zinc to phosphorus ratio decreases and the phosphorus to sulfur ratio increases.
Table 2: High resolution XPS analyses of S2p and Zn2p over increasing areas of the early tribofilm
Analytical area
|
Tribofilm area
|
S2p -
sulfide %
|
S2p -
sulfate %
|
Zn2p -
ZnS %
|
Zn2p -
ZnO %
|
700 x 300 μm
|
0.2%
|
70.8%
|
29.2%
|
79.7%
|
20.3%
|
55 x 55 μm
|
13%
|
77.2%
|
22.8%
|
84.0%
|
16.1%
|
27 x 27 μm
|
54%
|
82.4%
|
17.6%
|
91.9%
|
8.1%
|
Extrapolated
|
100%
|
91.6%
|
8.5%
|
101%
|
0%
|
The P 2p3/2 binding energy appears at around 133.9 eV indicating the presence of phosphate species [20]. The S 2p3/2 binding energies appear at 162.8 eV and 168.8 eV and can be assigned, respectively, to sulfide [21] and sulfate [22]. The Zn 2p3/2 binding energy appears at ~ 1020.5 eV and 1022.0 eV and is attributed to the contributions of ZnO [23] and ZnS [24] compounds respectively. Based on these analyses and peak fitting of the high resolution XPS spectra shown in Fig. 9, the changes in the ratio of sulphide/sulphate and ZnS/ZnO ratios were calculated for the three sampling areas (and extrapolated to 100% tribofilm) and are presented in Table 3. The thermofilm is clearly more oxidised than the tribofilm as most sulfate is in the thermofilm. Oxidised zinc (i.e. ZnO) decreases to around zero in the tribofilm while ZnS increases to around 100%. This is because the tribofilm surface is continuously generated, but the thermofilm develops in a constant oxidative state due to the thermal decomposition of the ZDDP additive.
Vibrational spectroscopy
The AFM-IR analytical positions on the stepped tribofilm are indicated in Fig. 6 and the resulting absorption spectra, averaged to reduce background noise, are shown in Fig. 7 (900–1800 cm− 1) and Fig. 8 (2600–3700 cm− 1). The 3rd (30 nm thick) and 4th layers (15 nm thick) comprise chemistries from the early period of tribofilm growth. These thinner films (and the tribofilm) are dominated by a broad band centred at ~ 1110 cm− 1, which shifts up in wavenumber as the tribofilm thickens. This band we assign to sulfate on the basis of strong S = O absorptions around 1100 cm− 1 [25] and consistency with the XPS observation that sulfate decreases significantly in thicker films. We discount Piras’ suggestion [26] that adsorption in this region is related to phosphorus as the band lies outside both P = O (1320 − 1140 cm− 1) and P-O (950–1060 cm− 1). However, the shoulder at lower wavenumber (~ 1070 cm− 1) becomes stronger as the film thickens and we believe this represents the developing phosphate layer.
The merged 1st and 2nd layers of the tribofilm are thicker (50–120 nm) and comprise the most developed film chemistry. The S = O absorbance at 1110 cm− 1 is less prominent while the band at ~ 1220 cm− 1 can be assigned to P = O with P-O appearing at 1070 and 1020 cm− 1. Stretching vibrations of P-O-C and P-O-P are at 968 cm− 1 and 928 cm− 1 and correspond to proposed polyphosphate chains in the tribofilm volume. This is consistent with XPS results, which showed an increase in phosphorus as the tribofilm develops. It also fits with Zhang and Spikes’ model [4] where, under sliding conditions, sulphur initially binds to the surface before a Zn and P rich tribofilm layer develops. Finally, the bands at 1712 cm− 1 and 1596 cm− 1 detected in the thickest first and second layers, are characteristic of carbonyl (C = O) and alkene (C = C) respectively.
In the upper AFM-IR spectral range (2600–3700 cm− 1) spectra are similar across the different layers in the structure. In all cases, the C-H stretch of an alkene can be identified between 3072 and 3140 cm− 1 and symmetric and an asymmetric CH2/CH3 stretching was assigned to absorbance around 2960 cm− 1 and 2870 cm− 1 respectively. The broad absorption peak between 3200 and 3650 cm− 1 is due to OH stretch. Finally, the stretching vibration observed at around 2784 cm− 1 gradually intensifies from the thermo-film towards the centre of the structure and appears in combination with the C = O bond in the lower range of the spectrum, therefore could be assigned to a H-(C = O) of an aldehyde.
Compositional variation in the ZDDP tribofilm
We observe a two-layer compositionally varied tribofilm (Fig. 9) where the thermal film and early stage tribofilm (< 15 nm thick) is partially oxidised and contains zinc sulfide, zinc sulfate and zinc oxide with limited amounts of phosphorus. However, as the tribofilm grows beyond 30 nm, phosphate / polyphosphate begins to form the bulk of the film while oxidised zinc and sulfate species are substituted by zinc sulfide.