Turbulent melt lubrication and current-carrying dynamic characterizations of the contact interface under magneto-thermal effect

Abstract

Under high-speed and high-temperature current-carrying conditions, turbulence in the metal liquefaction layer significantly influences friction interface performance, especially in a magneto-thermal shock environment. The interplay between turbulence and interface roughness complicates the dynamic behavior of hybrid lubrication and electrical contact. To explore the underlying mechanisms, this study constructs a turbulent melt lubrication model by integrating magnetic, temperature, and tribological calculations using the finite difference method (FDM). The findings reveal that armature velocity variations notably affect interface heat distribution, causing melt waves to propagate along the contact interface. As working conditions change, the primary heat source at the interface shifts from Joule heat to a combination of viscous and Joule heat (63.81 % and 36.19 %, respectively), demonstrating the complexity of the energy conversion process. Notably, the formation of a metal liquefied layer reduces the coefficient of friction and alters the lubrication state, which is crucial for optimizing the performance of electromagnetic launching system (EMLs).