The concept of critical operating conditions, the band of operating li
nes which marks the transition from stable to unstable operation, is p
resented to study the behaviour of the head-disk interface (HDI) under
ultra-low flying conditions. The level of slider-disk interaction res
ulting from intermittent contact at the HDI is used as the criterion f
or this transition. Critical conditions have been determined experimen
tally for three-rail mini-monolithic ferrite sliders flying in air and
helium over a carbon-coated thin-film disk, and are compared to numer
ical results obtained from a simple scaling analysis. A flying tester
has been developed to investigate constant velocity, ultra-low flying
height operation over a range of velocities and ambient pressures. Acc
elerated wear of thin-film media has also been investigated with this
apparatus. Utilizing a linear velocity slightly higher than the critic
al value, it is possible to delay failure for several hours to several
days. Worn slider and disk surfaces have been examined using optical
and scanning electron microscopy, and debris has been characterized us
ing Auger electron spectroscopy. These observations, coupled with meas
urement of the friction force, have enhanced understanding of the wear
process leading to failure under dry, unlubricated conditions.