Foil (metal)
A foil is a very thin sheet of metal, usually made by hammering or rolling. Foils are most easily made with malleable metals, such as aluminium, copper, tin, and gold. Foils usually bend under their own weight and can be torn easily. The more malleable a metal, the thinner foil can be made with it. For example, aluminium foil is usually about 1/1000 inch (0.03 mm), whereas gold (more malleable than aluminium) can be made into foil only a few atoms thick, called gold leaf. Extremely thin foil is called metal leaf. Leaf tears very easily and must be picked up with special brushes.
Tribocorrosion
While tribocorrosion phenomena may affect many materials, they are most critical for metals, especially the normally corrosion resistant so-called passive metals. The vast majority of corrosion resistant metals and alloys used in engineering (stainless steels, titanium, aluminium etc.) fall into this category. These metals are thermodynamically unstable in the presence of oxygen or water and they derive their corrosion resistance from the presence at the surface of a thin oxide film, called the passive film, which acts as a protective barrier between the metal and its environment. Passive films are usually just a few atomic layers thick. Nevertheless, they can provide excellent corrosion protection because if damaged accidentally they spontaneously self-heal by metal oxidation. However, when a metal surface is subjected to severe rubbing or to a stream of impacting particles the passive film damage becomes continuous and extensive. The self-healing process may no longer be effective and in addition it requires a high rate of metal oxidation. In other words, the underlying metal will strongly corrode before the protective passive film is reformed, if at all. In such a case, the total material loss due to tribocorrosion will be much higher than the sum of wear and corrosion one would measure in experiments with the same metal where only wear or only corrosion takes place. The example illustrates the fact that the rate of tribocorrosion is not simply the addition of the rate of wear and the rate of corrosion but it is strongly affected by synergistic and antagonistic effects between mechanical and chemical mechanisms. To study such effects in the laboratory, one most often uses mechanical wear testing rigs which are equipped with an electrochemical cell. This permits one to control independently the mechanical and chemical parameters. For example, by imposing a given potential to the rubbing metal one can simulate the oxidation potential of the environment and in addition, under certain conditions, the current flow is a measure of the instantaneous corrosion rate. Volume loss due to electrochemical dissolution can be measured by Faraday's laws of electrolysis and subtracted from total volume loss in tribocorrosion so the sum of mechanical wear loss and the synergies can be calculated. For a deeper understanding tribocorrosion experiments are supplemented by detailed microscopic and analytical studies of the contacting surfaces.