Prof. Erik Johansson
1
Dr. Lars Nilsson
1
Prof. Maria Holm
1
4
Department of Materials Science, KTH Royal Institute of Technology, Stockholm, Sweden
4
Department of Mechanical Engineering, Chalmers University of Technology, Gothenburg, Sweden
4
Department of Mechanical Engineering, Chalmers University of Technology, Gothenburg, Sweden
Abstract
Understanding the contact behavior of rough surfaces is fundamental to predicting and controlling friction, wear, adhesion, and sealing in numerous engineering applications. A critical aspect of this behavior is the real area of contact, which is typically orders of magnitude smaller than the nominal contact area. Furthermore, under combined normal and tangential loading, the real area of contact can increase, a phenomenon known as junction growth. While theoretical models and numerical simulations have provided valuable insights into contact mechanics and junction growth, experimental validation, particularly for non-transparent materials and complex rough surfaces, remains challenging. This article presents a review of experimental investigations into the evolution of the real contact area and junction growth in rough contacts, with a specific focus on the application of X-ray computed tomography (X-ray CT). The principles of using X-ray CT for visualizing and quantifying the real contact area are discussed, along with typical experimental methodologies and findings. The analysis highlights the capability of X-ray CT to provide three-dimensional, non-destructive insights into the buried interface of rough contacts under various loading conditions, enabling a more direct experimental assessment of junction growth compared to traditional surface-based techniques. Challenges and future prospects of using X-ray CT and other advanced experimental methods for understanding rough contact behavior are also discussed.
How to Cite
Prof. Erik Johansson, Dr. Lars Nilsson, & Prof. Maria Holm. (2025). Contact Area Evolution In Rough Surfaces: A Comprehensive X-Ray CT Study. Frontiers in Emerging Engineering & Technologies, 2(06), 16β20. Retrieved from https://irjernet.com/index.php/feet/article/view/119
Hertz, H., On the contact of elastic solids. Journal fΓΌr die reine und angewandte Mathematik. 92: 156β171 (1881).
Archard J F. Elastic deformation and the laws of friction. P R Soc A 243(1233): 190β205 (1957)
Greenwood J A, Williamson J B P. Contact of nominally flat surfaces. P R Soc A 295(1442): 300β319 (1966)
Chang W R, Etsion I, Bogy D B. An elastic-plastic model for the contact of rough surfaces. J Tribol 109(2): 257β263 (1987)
Bush A W, Gibson R D, Thomas T R. The elastic contact of a rough surface. Wear 35(1): 87β111 (1975)
Persson B N J. Theory of rubber friction and contact mechanics. J Chem Phys 115(8): 3840β3861 (2001)
Persson B N J. On the fractal dimension of rough surfaces. Tribol Lett 54(1): 99β106 (2014)
Persson B N J. Contact mechanics for randomly rough surfaces. Surf Sci Rep 61(4): 201β227 (2006)
Cohen D, Kligerman Y, Etsion I. A model for contact and static friction of nominally flat rough surfaces under full stick contact condition. J Tribol 130(3): 031401β031409 (2008)
Brizmer V, Kligerman Y, Etsion I. A model for junction growth of a spherical contact under full stick condition. J Tribol 129(4): 783β790 (2007)
Brizmer V, Kligerman Y, Etsion I. Elastic-plastic spherical contact under combined normal and tangential loading in full stick. Tribol Lett 25(1): 61β70 (2007)
Wu A Z, Shi X, Polycarpou A A. An elastic-plastic spherical contact model under combined normal and tangential loading. J Appl Mech 79(5): 051001β051009 (2012)
Shi X, Wu A Z, Zhu C M, Qu S X. Effects of load configuration on partial slip contact between an elastic plastic sphere and a rigid flat. Tribol Int 61: 120β128 (2013)
Wang X Z, Xu Y, Jackson R L. Elastic-plastic sinusoidal waviness contact under combined normal and tangential loading. Tribol Lett 65(2): 45 (2017)
Wang X Z, Xu Y, Jackson R L. Theoretical and finite element analysis of static friction between multi-scale rough surfaces. Tribol Lett 66(4): 146 (2018)
Wang X Z, An B W, Xu Y, Jackson R L. The effect of resolution on the deterministic finite element elastic-plastic rough surface contact under combined normal and tangential loading. Tribol Int 144: 106141 (2020)
Wang R L, Liu J H, Zhang F K, Ding X Y. An approach to evaluate the sealing performance of sealing structures based on multiscale contact analyses. J Comput Des Eng 8(6): 1433β1445 (2021)
Dyson J, Hirst W. The true contact area between solids. Proc Phys Soc B 67(4): 309β312 (1954)
Bhushan B. The real area of contact in polymeric magnetic mediaβII: Experimental data and analysis. Asle Trans 28(2): 181β197 (1985)
Bhushan B, Dugger M T. Liquid-mediated adhesion at the thin film magnetic disk/slider interface. J Tribol 112(2): 217β223 (1990)
Dieterich J H, Kilgore B D. Direct observation of frictional contacts: New insights for state-dependent properties. Pure Appl Geophys 143(1): 283β302 (1994)
Visscher M, Hendriks C P, Struik K G. Optical profilometry and its application to mechanically inaccessible surfaces Part II: Application to elastometer/glass contacts. Precis Eng 16(3): 199β204 (1994)
Hendriks C P, Visscher M. Accurate real area of contact measurements on polyurethane. J Tribol-T Asme 117(4): 607β611 (1995)
Lo S-W, Tsai S-D. Real-time observation of the evolution of contact area under boundary lubrication in sliding contact. J Tribol 124(2): 229β238 (2002)
Castillo J, Blanca A P D L, Cabrera J A, Simon A. An optical tire contact pressure test bench. Vehicle Syst Dyn 44(3): 207β221 (2006)
Matsuda K, Hashimoto D, Nakamura K. Real contact area and friction property of rubber with two-dimensional regular wavy surface. Tribol Int 93: 523β529 (2016)
Bennett A I, Harris K L, Schulze K D, Uruena J M, McGhee A J, Pitenis A A, MΓΌser M H, Angelini T E, Sawyer W G. Contact measurements of randomly rough surfaces. Tribol Lett 65(4): 134 (2017)
Tabor D. Junction growth in metallic friction: The role of combined stresses and surface contamination. P R Soc A 251(1266): 378β393 (1959)
Parker R C, Hatch D. The static coefficient of friction and the area of contact. Proc Phys Soc B 63(3): 185β197 (1950)
Courtney-Pratt J S, Eisner E. The effect of a tangential force on the contact of metallic bodies. P Roy Soc Lond A Mat 238(1215): 529β550 (1957)
Constantinou C P, Chaudhri M M. Optical observations of βjunction growthβ in asperities of copper, aluminium, PTFE and nylon under combined normal and tangential stresses. J Mater Sci 24(12): 4279β4292 (1989)
Ovcharenko A, Halperin G, Etsion I, Varenberg M. A novel test rig for in situ and real time optical measurement of the contact area evolution during pre-sliding of a spherical contact. Tribol Lett 23(1): 55β63 (2006)
Ovcharenko A, Halperin G, Etsion I. In situ and real-time optical investigation of junction growth in spherical elastic-plastic contact. Wear 264(11β12): 1043β1050 (2008)
Ovcharenko A, Halperin G, Etsion I. Experimental study of adhesive static friction in a spherical elastic-plastic contact. J Tribol 130(2): 021401 (2008)
Kucharski S, Starzynski G. Contact of rough surfaces under normal and tangential loading. Wear 440β441: 203075 (2019)
Bettscheider S, Gachot C, Rosenkranz A. How to measure the real contact area? A simple marker and relocation foot-printing approach. Tribol Int 103: 167β175 (2016)
Xu Y, Chen Y, Zhang A Q, Jackson R L, Prorok B C. A new method for the measurement of real area of contact by the adhesive transfer of thin Au film. Tribol Lett 66(1): 32 (2018)
Persson B N J, Albohr O, Tartaglino U, Volokitin A I, Tosatti E. On the nature of surface roughness with application to contact mechanics, sealing, rubber friction and adhesion. J Phys-Condens Mat 17(1): R1βR62 (2005)
Zhang F K, Liu J H, Ding X Y, Wang R L. Experimental and finite element analyses of contact behaviors between non-transparent rough surfaces. J Mech Phys Solids 126: 87β100 (2019)
Zhang F K, Liu J H, Ding X Y, Yang Z M. A discussion on the capability of X-ray computed tomography for contact mechanics investigations. Tribol Int 145: 106167 (2020)
Otsu N. A threshold selection method from gray-level histograms. Ieee T Syst Man Cyb 9(1): 62β66 (1979).