Effects of micro-deformation on the stick-slip and wear behaviors of galvanized steel

In the automotive industry, squeak and rattle (S&R) noise caused by stick-slip phenomena and wear-induced clearances adversely affect ride safety and passenger comfort, leading to substantial warranty-related costs. This study investigated micro-deformation as a surface modification approach to simultaneously address stick-slip behavior and enhance wear resistance in galvanized steel. Friction, vibration, and noise of galvanized steel specimens with various deformations (0.2%, 1.5%, and 2.2%) were analyzed. Results demonstrated that micro-deformation exceeding 1.5% effectively mitigated stick-slip behavior by reducing asperity density within a specific scale range. Furthermore, the micro-deformation induced compressive residual stress through decreased interplanar crystal spacing, consequently reducing wear scar depth by 84%. These findings suggest that micro-deformation is an effective solution for noise mitigation in automotive galvanized steel applications.