Solid Lubricant Research Articles

Tribological Properties of 7A04 Aluminum Alloy Enhanced by Ceramic Coating

The 7A04 Al alloy is a commonly used lightweight metal material; however, its low wear resistance limits its application. In this study, the wear resistance of this alloy was improved by preparing micro-arc oxidation (MAO) coatings, MAO/MoS2 composite coatings, and hard-anodized (HA) coatings on its surface. The friction and wear behaviors of these three coatings with diamond-like coated (DLC) rings under oil lubrication conditions were investigated using a ring–block friction tester. The wear rates of the coatings on the block surfaces were determined using laser confocal microscopy, and the wear trajectories of the coatings were examined using scanning electron microscopy. The results indicated that, among the three coatings, the MAO/MoS2 coating had the lowest coefficient of friction of 0.059, whereas the HA coating had the lowest wear rate of 1.47 × 10−6 mm/Nm. The MAO/MoS2 coatings exhibited excellent antifriction properties compared to the other coatings, whereas the HA coatings exhibited excellent anti-wear properties. The porous structure of the MAO coatings stored lubricant and replenished the lubrication film under oil lubrication. Meanwhile, the introduced MoS2 enhanced the densification of the coating and functioned as a solid lubricant. The HA coating exhibited good wear resistance owing to the dense structure of the amorphous-phase aluminum oxide. The mechanisms of abrasive and adhesive wear of the coatings under oil lubrication conditions and the optimization of the tribological properties by the solid–liquid synergistic lubrication effect were investigated. This study provides an effective method for the surface modification of Al alloys with potential applications in the aerospace and automotive industries.

Environmentally Friendly MoS2-hBN Solid Lubricants: A Comprehensive Tribological Evaluation

Abstract MoS2-based solid lubricants have obtained significant attention and are extensively employed in the aerospace industry due to their desirable tribological performance. However, to enhance their performance in humid environments, MoS2 is often doped with Pb-based compounds. Considering the health and environmental concerns associated with Pb, it is necessary to develop eco-friendly alternatives. In this study, hexagonal boron nitride (hBN) has been used as a potential substitute for Pb-based dopants in MoS2-based solid lubricants and coatings with varying hBN contents (9.5, 11.5, 13.5, 15.5, and 17.5 wt%) were applied to stainless-steel substrates using a spray bonding technique. The friction and wear characteristics of the coatings were analyzed by using a ball-on-flat tribometer, employing constant load conditions. Subsequently, ex situ analysis techniques such as scanning electron microscopy, Raman spectroscopy, and atomic force microscopy were used to characterize the coatings. The results showed that the coating with a lower hBN concentration presented improved tribological properties, which was correlated with the development of an effective MoS2-based transfer/tribo-film. This suggests that optimizing hBN content is crucial for enhancing the lubrication performance.

A Different Perspective on the Solid Lubrication Performance of Black Phosphorous: Friend or Foe?

Black phosphorous (BP), a promising 2D material with exceptional electronic and optical properties, has shown remarkable potential in tribology as an additive in liquid lubrication and a composite in solid lubrication. However, its potential as the standalone solid lubricant is still at its early stage. This study evaluates BP's solid lubrication performance as deposited coating (by drop casting) on a variety of metallic substrates (polished AISI 52 100 steel, aluminum, copper, and iron) under different contact pressures using a ball‐on‐disc linear‐reciprocating test machine in dry conditions. The results demonstrate that BP does not systematically reduce friction and wear. Depending on the contact pressure and the characteristic of the substrate material (particularly surface roughness), its friction and wear behavior vary a great deal. The best results observed are a 33% reduction in friction with increased surface roughness on iron and a 23% reduction in wear on aluminum. While no general trend is observed for contact pressure effects, increased substrate roughness proves beneficial, enhancing lubricant retention and exploiting BP's low interlayer shear mechanism. Therefore, this study demonstrates that while promising, BP's solid lubrication performance is not exceptional. It also highlights the importance of optimizing test conditions and materials for enhanced lubrication.

Experimental Investigations of Friction Properties of Carbon Particles Derived from Sargassum Algae

In Caribbean islands, the washing ashore of tons of pelagic Sargassum spp., consisting of two species Sargassum fluitans and Sargassum natans, has been regularly occurring since 2011. As green lubrication is a growing trend in the tribology industry, biochar is a promising alternative. Sargassum biochars, produced from Sargassum pelagic algae, are therefore being studied as solid lubricants. This study aims to explore their potential applications. Biochars from brown algae were pyrolyzed at 400 °C and then annealed at different temperatures (from 600 °C to 1500 °C). The Raman spectra collected on the different biochars showed that there was a structural organization of the biochars as the temperature increased. The tribologic properties of the biochars were studied and compared to a solid lubricant reference (exfoliated graphite). Raman spectroscopy analysis revealed a progressive structural reorganization with increasing temperature, leading to a 58% reduction in the coefficient of friction. The morphology and the structure of the tribofilm are investigated by profilometry, scanning electron microscopy, and Raman microspectrometry. Overall, these results can be considered as a first step for utilizing the biochar derived from brown algae Sargassum sp. as an additive in the lubricant industry, for the purpose of emission reduction.

Tribological behaviour of DIN 1.2740 hot working tool steel during mandrel mill stretching process

This study evaluates the tribological properties of DIN 1.2740 hot tool steel against Super Cr13 martensitic stainless steel at 700°C. The results show that the coefficient of friction (COF) ranged from 0.15 to 0.63, indicating moderate frictional interaction. The wear rate of DIN 1.2740 was observed to be low, suggesting good resistance to wear at high temperatures. The complex surface oxide layer that formed on the pin’s top surface, significantly reducing the COF and acting as a solid lubricant at elevated temperatures. The oxide layer was also fragile and unable to withstand the high sliding velocities and high loads. The steel exhibited a high surface roughness when subjected to increasing normal loads and increasing sliding velocities.

Fabrication of Cu-Doped Diamond-like Carbon Film for Improving Sealing Performance of Hydraulic Cylinder of Shearers

During shearer operation, the piston rod is susceptible to wear from the invasion of pollutants, thus ruining the sealing ring in the hydraulic cylinder. This work attempts to conduct a systematic investigation of Cu-doped diamond-like carbon (Cu-DLC) film to improve the seal performance. The failure process of the cylinder was analyzed, and relevant parameters were determined. Several Cu-DLC films were deposited on the substrate of the piston rod in a multi-ion beam-assisted system, and their structures and combined tribological performances were investigated. The hardness of the film ranges from 27.6 GPa to 14.8 GPa, and the internal stress ranges from 3500 MPa to 1750 MPa. The steady-state frictional coefficient of the film ranges from 0.04 to 0.15; the wear rate decreases first and then increases, and it reaches its lowest (5.0 × 10−9 mm3/N·m) at 9.2 at.% content. a:C-Cu9.2% film presents optimal combined tribological performances in this experiment. The modification mechanism of Cu-DLC film for the seal performance may come from the synergistic effects of (i) the contact force and friction-heat-induced film graphitization, (ii) Cu doping improves the toughness of the film and acts as a solid lubricant, and (iii) the transfer layer plays a role in self-lubrication.

Sustainable Grease Lubrication Induced by Graphene Oxide and LiFePO4

This study investigates the possibility of modifying lubricating greases by 2D graphene oxide (GO) and lithium iron phosphate (LiFePO4) to enhance their tribological performance. GO's layered structure plays a crucial role in reducing friction by facilitating easy sliding between rubbing surfaces, making it an effective solid lubricant. The impact of these additives on friction reduction, wear resistance, and the tribolayer formation ability is evaluated by ball‐on‐disc tribometry with an emphasis on durability and sustainability. Comparative results reveal that unmodified greases exhibit a high susceptibility to wear, including oxide formation and severe plastic deformation. In contrast, greases with GO show a notable reduction in friction, while the addition of LiFePO4 contributes to the formation of a continuous protective layer that substantially reduces abrasive wear. The combination of GO and LiFePO4 results in a homogeneous, durable tribofilm that effectively protects surfaces against severe wear providing long‐term friction stability. Although lab‐scale LiFePO4 is used, the findings suggest a great potential for extending the useful life of recycled LiFePO4 from lithium‐ion batteries, similar to commercial LiFePO4 thus confirming significant improvements in the grease performance but also highlighting the potential to advance toward more sustainable solutions in industrial applications and electric vehicles.

Shrouding Gas Plasma Deposition Technique for Developing Low-Friction, Wear-Resistant WS2-Zn Thin Films on Unfilled PEEK: The Relationship Between Process and Coating Properties

In this study, tungsten disulfide–zinc (WS2-Zn) composite films were generated on polyether ether ketone (PEEK) disks by an atmospheric pressure plasma jet (APPJ) equipped with a shrouding attachment. The friction and wear properties of the WS2-Zn coatings were intensively investigated by using a rotational ball-on-disk setup under dry sliding and ambient room conditions. In order to gain more information about the lubrication mechanism, the coating areas as deposited and the worn areas (i.e., in the wear track) were analyzed with a scanning electron microscope (SEM) with regard to their chemical composition in depth by energy-dispersive X-ray spectroscopy (EDS). X-ray photoelectron spectroscopy (XPS) was conducted to obtain precise chemical information from the surface. The results indicated that WS2-Zn coatings significantly improved the tribological properties, exhibiting a coefficient of friction (COF) of <0.2. However, the tribological performance of the coatings is strongly dependent on the plasma process settings (i.e., plasma current, dwell time of the powder particles in the plasma jet), which were tuned to reduce the oxidation by-products of WS2 to a minimum. The COF values achieved of the dry lubricant films were significantly reduced in contrast to the uncoated PEEK by a factor of four.

The Impact of Hydrostatic Pressure on the Structural, Mechanical, Thermal, and Optoelectronic Characteristics of the RbV3Sb5 Kagome Compound: Ab initio Approach.

We studied the RbV3Sb5 kagome compound's structural, mechanical, thermal, and optoelectronic properties. Mulliken and Hirshfeld population analysis found ionic and covalent connections in RbV3Sb5. The Born stability criterion shows that pure RbV3Sb5 is mechanically stable. The precise measurement of 3.96 indicates that our sample has higher machinability at 20 GPa. Low anticipated hardness of RbV3Sb5 suggests it can be used as a soft solid lubricant. Hardness ratings rise with pressure, however there are exceptions. Pressure causes large nonmonotonic changes in RbV3Sb5's anisotropic characteristics. A comparable 20 GPa Zener anisotropic value, RbV3Sb5 has the highest. The structure's projected Debye temperature at 0 GPa is 284.39 K, indicating softness. Dispersion curves with negative frequencies suggest ground state structural dynamical instability. The structure has no negative-energy phonon branches under 10 GPa stress. From band structure and density of state analysis, the structure behaves metallically under hydrostatic pressure. Also, the structure has maximal ultra-violet conductivity and absorption. The absorption coefficient, conductivity, and loss function plots show uniform patterns at all pressures. As pressure rises, these graphs' peaks blue shift.

Difference in High-Temperature Tribological Performance of Oxide/Ag-MoS2-Based Composites

MoS2 has excellent vacuum lubricating performance. However, it is prone to be oxidized in a high-temperature atmospheric environment, leading to the deterioration of its lubricating performance and even serious space accidents. The high-temperature lubricating performance of MoS2-based solid lubricating materials can be improved to some extent by the co-compounding of appropriate oxides and Ag. The tribological properties of several common nano-oxides (ZnO, TiO2, Al2O3, and ZrO2) composited with metal Ag of MoS2-based composites were compared at 450 °C. The results showed that the comprehensive tribological performance of MoS2-TiO2-Ag was the best, an the average friction coefficient of about 0.26, and a wear rate of about 1.2 × 10−5 mm3/Nm, which was 18% and 43% lower than that of MoS2-Ag, respectively. The excellent tribological properties of MoS2-TiO2-Ag composites were attributed to three aspects: Firstly, with the help of the oxidation resistance of TiO2 to MoS2 to some extent and its high ionic potential, its oxidation resistance was improved and its shear strength was reduced to provide low friction. Secondly, relying on the low shear strength and good film-forming tendency of soft metal Ag on the sliding surface, a low shear tribo-film was easily formed on the friction interface, which was helpful for the synergistic lubrication of Ag, MoS2, and TiO2.Thirdly, through the matching of hard TiO2 and soft Ag, the wear resistance and bearing capacity of the composites were improved to some extent. The research results can provide some reference for the selection and design of MoS2-based high-temperature lubricating materials and the enhancement of their tribological properties.

Enhancing tribological performance of AISI 52100: the role of laser surface texturing in dry and lubricated conditions

Abstract Laser surface texturing (LST) is a valuable technique in surface engineering that offers significant improvements in the tribological behavior of metals and alloys. This study investigates the synergistic effect of incorporating hexagonal boron nitride (h-BN) as a solid lubricant with laser surface texturing on the tribological performance of AISI 52100. Dimple textures with varying pitch distances (100, 150, and 200 μm) were created on the surfaces of the mentioned materials using LST. The friction coefficient and wear behavior of both non-textured surface (NTS) and textured surfaces (TS) were analyzed under dry sliding (DS) and lubricating sliding (LS) conditions. Wear tests were conducted using a universal tribometer under a load of 10 N, a sliding frequency of 10 Hz, and a sliding time of 1250 s. The results demonstrate that the presence of dimple textures significantly influences the tribological behavior of the materials. In DS, the wear coefficient exhibits a significant reduction compared to NTS, with decreases of 88.1% for TSP-100, 28.5% for TSP-150, and 76.1% for TSP-200. In LS, the TSP-L-100 (h-BN NPS) surface demonstrates the lowest average wear coefficient among all textured surfaces. Specifically, the TSP-L-100 surface shows a remarkable 97.61% reduction in average wear coefficient compared to NTS. This study demonstrates the potential of LST combined with h-BN as a solid lubricant in improving the tribological properties of metals, offering valuable insights for surface engineering applications in various industries.

Influence of heat treatment on metallurgical and mechanical properties of aluminium Al6061 hybrid metal matrix composites

Abstract The current investigation explores the metallurgical and mechanical properties of hybrid metal matrix composites (HMMC) with aluminum 6061 as the base material, reinforced with ceramic of tungsten carbide (WC) nanoparticles, graphite (as a solid lubricant) and redmud (RM). Four different composites with tungsten carbide nanoparticles (1.5 wt.%) and graphite (2 wt.%) with a varying proportions of redmud (0, 1, 3 and 5 wt.%) are fabricated by stir casting. Microscopic analysis reveals grain boundary with segregations, some of which dissolve to form discontinuous grain boundaries after heat treatment. FESEM examination shows the formation of intermetallic, some of which dissolve on heat treatment to form precipitate that are distributed evenly along the grain boundary and also inside grains. EDX mapping further validated the uniform distribution of reinforcements without any agglomeration. The addition of reinforcements and heat treatment (T6) resulted in substantial improvements in hardness, ultimate tensile strength, yield strength, and compressive strength compared to unreinforced Al6061 and untreated HMMC, respectively. Fractographic analysis of tensile tested samples reveals the presence of dimples, tearing edges and small voids, indicating ductile fracture.

Using a bonded solid film lubricant to prevent fretting wear in the axle journal bearings of rail vehicles

Fretting degrades the inboard inner ring and the backing ring contact surfaces of axle journal roller bearings used in railway applications. This study attempts to prevent fretting wear between them as well as fretting wear particles from entering the axle bearing interior without introducing new bearing components. It has been reported that coating metallic surfaces with bonded solid film lubricants improves lubricity and wear resistance while reducing fretting wear. To evaluate the impact on fretting wear prevention, a full-size railway axle bearing that was coated a backing ring side face with a bonded solid film lubricant was rotated. The findings demonstrate that applying the bonded solid film lubricant to the backing ring side face does not prevent the axle bearings from fretting. The surface temperature probably exceeds the heat-resistant temperature of the solid film lubricant because of the fretting friction.

Transition metal carbo chalcogenides: A novel family of 2D solid lubricants

Two-dimensional (2D) layered materials such as transition metal dichalcogenides (e.g., MoS2, WS2) and MXenes (e.g., Ti3C2Tx), as well as hybrids of these materials are the focus of current research in solid lubrication due to their outstanding performance. Transition metal carbo-chalcogenides (TMCCs), consisting of an MXene core and a TMD-like surface, represent an inherent combination of TMDs and MXenes without the need to construct hybrids out of the individual layers. Due to their layered structure and surface chemistry, favorable tribological properties can be expected from these novel materials. Here, multilayer Ta2S2C and Nb2S2C TMCCs are deposited solely as a powder onto a steel substrate and their tribological properties under linear sliding against different counterbodies, i.e., Al2O3, SiC, 100Cr6, and polytetrafluoroethylene (PTFE) are discussed. Advanced materials characterization techniques are used to detect the presence of TMCCs inside the wear tracks and to reveal their 2D structure within the tribofilm. Finally, density functional theory (DFT) simulations are used to unravel the easy shearability of TMCCs at the nanoscale. The results demonstrate the great potential of this new 2D material family, which also offers many possibilities for defined tuning of the solid-solid interface.

Structural features of bimetallic composites of the Me-Al type (Cu, Ni, Nb), obtained by ball milling of powder mixtures and consolidation by torsion under pressure

A comparative study of the features of the microstructure of bimetallic composites of the Me-Al (Cu, Ni, Nb) type, obtained by ball milling of powder mixtures and consolidation by torsion under pressure in Bridgman anvils, was carried out. In all systems studied in this work, the formation of a nanoband structural state is observed, the elements of which are elongated predominantly along the direction parallel to the anvil plane. It has been established that in local areas characterized by the absence of the aluminum component, an SMC state without a nanolaminate structure is formed. An analysis of the features of structure formation was carried out taking into account the comparison of the characteristics of powder systems components (melting point, shear modulus and stacking-fault energy). It was shown that low shear modulus of aluminum, compared to other components, in combination with a higher homologous temperature, provides it high accommodative ability. It has been suggested that under conditions of torsion under pressure, the aluminum component, being a kind of solid lubricant, ensures slipping and flattening of stronger layers of the second component, which contributes to the formation of a nanolaminate structure in the metal‑aluminum systems under consideration.

A review on progress trends of machining of Carbon Fiber Reinforced Plastics

In contemporary manufacturing industries, composite materials such as carbon fiber reinforced plastics (CFRPs) have become indispensable, finding extensive applications in aerospace, automotive, shipbuilding, high-tech sports equipment, and more. The exceptional chemical, physical, and mechanical properties of CFRPs, including high corrosion resistance, superior strength-to-weight ratio, high fatigue strength, and oxidation resistance, make them highly sought after. However, these very advantages pose significant challenges during machining due to the abrasive nature of composites, anisotropic mechanical properties, and poor thermal conductivity, which collectively exacerbate tool wear. This review paper addresses the critical need for innovative solutions to improve the machinability of CFRPs, a subject of paramount importance for advancing manufacturing efficiency and product quality. It comprehensively examines the latest research progress, current practices, and emerging trends in machining techniques such as turning, drilling (including reaming and countersinking), milling and grinding. The review delves into the influence of various cutting conditions, environments, and tool geometries. It also examines tool textures, materials, and coatings. Additionally, advanced machining methods, including vibration, thermal, and hybrid-assisted machining, are discussed. These factors impact key performance metrics such as cutting forces and torques, tool wear and life, chip morphology, surface roughness, and the quality of machined surfaces, including defect analysis. By synthesizing a vast array of literature for the first time, this paper highlights the most effective strategies to enhance machinability while extending tool life and improving surface finish. Notably, it underscores the innovative use of dry and flood lubrication, minimum quantity lubrication, cryogenic lubrication, and high-pressure cooling. Additionally, it emphasizes optimizing cutting tool geometry, employing diamond tools, and coating tools with TiN and TiAlN, alongside the application of heat treatment and hybrid machining methods, particularly those incorporating vibration machining techniques. This review not only identifies the current challenges but also proposes cutting-edge solutions, making it an essential resource for researchers and practitioners aiming to push the boundaries of CFRP machining technology.

Fluorine containing diamond-like carbon coatings

Fluorine containing diamond-like carbon (DLC) coatings were obtained by CVD deposition using the destruction of gaseous hydrocarbons by a high-energy ion source with an anode layer. The chemical composition, structure, surface energy, mechano-tribological characteristics of the synthesized thin-film material were studied. It has been shown that the fluorine content in the deposited coatings reaches 31 at.%. It has been established that the presence of fluorine in the DLC coating promotes the formation of nanodispersed graphite-like structures. Fluorine containing coatings with a high content of sp2 hybridized carbon atoms and graphite fragments show a decrease in hardness. Such coatings have a very low coefficient of friction at the level of 0.03–0.07 due to the low surface energy, which can be reduced by 1.5 times compared to pure DLC. It has been established that different fluorine contents in thin-film diamond-like carbon material have different effects on the interaction of the DLC coating with polar/non-polar dielectrics. The research results can be used for the technology of producing solid lubricants in friction units of machines and mechanisms, and are also of interest for medicine, the food industry, the production of plastics, and chemical fibers as chemically inert and corrosion-resistant coatings.

Enhancing thread cutting performance with CNT-embedded micro textured tools

ABSTRACT This paper investigates the impact of a CNT-embedded textured tool on the thread-turning process. The study aims to optimize the efficiency and effectiveness of the thread-turning by utilizing this innovative tool. The experimental research explores the performance of the tool in terms of generated cutting forces. The findings contribute to understanding the potential benefits of integrating CNT-embedded textured tools in the manufacturing industry, particularly for thread-turning operations. This study demonstrates that the linear textured tool embedded with CNT solid lubricant exhibits a significant 36.8% reduction in cutting forces compared to conventional cutting inserts.

Effect of coated graphene on friction and wear properties of nickel-based self-lubricating coatings prepared by laser cladding

Graphene is an ideal material for improving the self-lubricating properties of coatings, but the high-energy laser beam can damage graphene during the laser cladding process. Therefore, in this paper, amorphous silicon dioxide (SiO2) is used to surface coat graphene particles to obtain silica-coated graphene with core-shell structure (G@SiO2). By adding niobium carbide (NbC) as the ceramic reinforcing phase and G@SiO2 nanoparticles as the solid lubricant in Ni60, a self-lubricating composite coating was prepared on the surface of 45 steel matrix by laser cladding technology. It is shown that G@SiO2 can promote the grain refinement of NbC in the coating. On the other hand, the addition of G@SiO2 promotes the generation of hard phase of chromium carbide, which together with NbC improves the hardness of the material. The maximum microhardness of the composite coating was 946 HV, which was 302.7% higher than that of the 45 steel base material. The lowest coefficient of friction value of the coated material was 0.25, and the lowest wear amount was 2.45 × 106 μm3. Compared with the composite coating without added G@SiO2, the coefficient of friction of the coated material with the addition of G@SiO2 was reduced by 50% and wear amount was reduced by 62%.

Mechanical Properties and Tribological Study of Bottom Pouring Stir-Cast A356 Alloy Reinforced with Graphite Solid Lubricant Extracted from Corn Stover

The present work epitomises extracting the graphite (Gr) solid lubricant from the corn stover. The extracted Gr was incorporated as reinforcement in the A356 alloy (Al-7Si), and the effect of the Gr particles on the mechanical and tribological properties was investigated. In spite of this, the input process parameters for the dry sliding wear test at room temperature against the EN31 steel disc were optimised through ANOVA analysis. The fabricated A359—X wt% (X = 0, 2.5, 5, 7.5) composite through bottom pouring stir casting techniques was analysed microstructurally by using XRD and FESEM analysis. The micro Brinell hardness and tensile strength were investigated per ASTME10 and ASTME8M standards. A wear test was performed for the composite pins against the EN31 steel disc according to ASTM G99 specifications. The XRD analysis results depict the presence of carbon (C), aluminium (Al), and silicon (Si) in all the wt% of the Gr reinforcement. However, along with the elements, the Al2Mg peak was confirmed for the A356—7.5 wt% Gr composite and the corresponding cluster element was confirmed in FESEM analysis. The maximum micro Brinell hardness of 92 BHN and U.T.S of 123 MPa and % elongation of 7.11 was attained at 5 wt% Gr reinforcement due to uniform Gr dispersion in the A356 alloy. Based on the ANOVA analysis, the optimal process parameters were obtained at 20 N applied load, 1 m/s sliding velocity, and 1000 m sliding distance for the optimal wear rate of 0.0052386 g/km and 0.364 COF.