Fretting Tester


Rtec Instruments fretting testers allow to comprehensively characterize fretting wear from micron to macro scale. Ultra sensitive piezo based load cells, combined with rigid design, high stiffness holders, low floor noise and robust design provides quantitative fretting wear characterization of materials, interfaces, thin films, components etc.


To simulate real life scenarios the tests can be done in room temperature or heating conditions, during electrical contacts or in humid conditions. Its easiness of use and data interpretability makes this tester an ideal tool in hands of researchers or quality control engineers.

FFT-M

♦  FFT-M | High-Frequency Reciprocating Rig

FFT-1

♦  FFT-1 | High-Performance Fretting Wear Tester

FFT-2

♦  FFT-2 | Evaluate the fretting behavior of materials under controlled conditions

Table Of Contents

How does a fretting tester work?

Fretting testers from Rtec Instruments are advanced tribology systems designed to evaluate fretting wear, friction, and lubrication performance by simulating small-amplitude oscillatory motion between contacting surfaces. They operate with precision control of motion, generating high-frequency reciprocating displacement in the micrometer range to replicate real-world fretting conditions. Some models feature environmental control, enabling testing under varied conditions, including temperature, humidity, and lubrication adjustments. Additionally, automated data acquisition and analysis software streamline test result interpretation, making it easier to assess material performance across different applications.

What is Fretting?

Fretting wear is a test in where surface damage occurs between two counter surfaces which are in oscillated motion with small amplitude. At the contact point, lubricant/coating is squeezed out or the low amplitude motion does not permit the contact area to be re-lubricated / debris dislodges resulting in serious local wear. This type of wear causes two-body abrasion, adhesion and/or fretting fatigue wear. In machines and engines, fretting movements can be dangerous as it can lead to surface degradation and machine failure.

The Rtec Instruments fretting wear testing systems have industry leading specifications on both stroke and frequency. Stroke length from 10 µm with a maximum frequency of 300Hz can be controlled across a temperature range from -35°C up to 800°C. Additional sensors like acoustic emission and electrical contact resistance provide significant information of the fretting experiments.

The FFT series allows to comprehensively characterizing fretting wear from micro to macro scale. Ultra-sensitive piezo based load cells, combined with rigid design, high stiffness holders, low floor noise and robust design provides quantitative fretting wear characterization of materials, interfaces thin films, components, etc.

Applications for Fretting?

Electrical connectors

 

Electrical connector fretting refers to the microscopic wear and degradation that occurs at the contact interface of electrical connectors due to small, repeated relative movements, leading to increased contact resistance, signal loss, and potential failure. Its applications include reliability testing to assess connector durability under vibration, thermal expansion, and mechanical stress; automotive industry evaluations to prevent fretting-related failures in wiring harnesses, sensor connections, and electronic control units; and aerospace and defense applications to ensure long-term reliability in avionics, radar systems, and communication equipment. It is also crucial in consumer electronics, where repeated plugging and micro-movements can degrade electrical contacts in smartphones and laptops, as well as in industrial and power systems to prevent resistance increases and overheating in power distribution and control panels. Additionally, fretting analysis is essential in medical devices to ensure the reliability of electronic connections in life-saving equipment such as pacemakers, defibrillators, and imaging systems.

HFRR

 

HFRR (High-Frequency Reciprocating Rig) testing is primarily used to evaluate the lubricity, friction, and wear characteristics of fuels and lubricants, but it can also be applied to fretting wear studies under reciprocating motion. Its applications include lubricity assessment, measuring the effectiveness of fuels, oils, and additives in reducing friction and wear under fretting conditions; wear and friction studies, evaluating the wear resistance and frictional behavior of materials and coatings subjected to reciprocating contact; and surface interaction analysis, investigating material degradation mechanisms, including fretting-induced surface damage and adhesion. It is also used in fuel and lubricant research to test the impact of low-lubricity fuels, such as low-sulfur diesel, on fretting wear in fuel injection systems. Additionally, HFRR testing plays a role in automotive and aerospace applications by assessing fretting performance in components like injector nozzles, valve seats, and precision mechanical assemblies.

SRV

 

SRV (Schwingung, Reibung, Verschleiß) testing is used in fretting to evaluate the friction, wear, and lubrication performance of materials under oscillating motion. The Rtec Instruments fretting wear testing systems with the specialized SRV module simulate real-world conditions like fretting wear, fretting fatigue, and frictional behaviour in mechanical components. Applications include lubricant evaluation to assess the effectiveness of oils, greases, and additives in reducing fretting wear and friction; material wear studies to compare the wear resistance of different coatings, surface treatments, or materials; and contact fatigue analysis to simulate fretting fatigue in mechanical joints such as bolted connections and spline couplings. It is also widely used in aerospace and automotive industries for studying fretting wear in critical parts like bearings, gears, and engine components, as well as in biomedical applications to evaluate fretting corrosion in implants and prosthetic joints.