Wear and Friction in Hybrid and Additive Manufacturing Processes

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: 30 June 2025 | Viewed by 1429

Special Issue Editors


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Guest Editor
Department of Mechanical Engineering, Iowa State University, Ames, IA 50011, USA
Interests: additive manufacturing; tribology; surface engineering; failure analyses
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Special Issue Information

Dear Colleagues,

Tribology is the science of friction, wear, and lubrication, making it inherently inseparable from surface engineering. Additive manufacturing (AM) offers unique capabilities that can be leveraged to enhance the reliability of various tribological contacts. Hybrid manufacturing can provide enhanced capability by combining subtractive and/or transformative (e.g., peening or rolling) processes with additive ones. The operating life of components engaged in wide varieties of contacts is critical for their application in sectors such as biomedicine, energy, automotive, and aerospace. Accordingly, this Special Issue seeks to showcase research papers, short communications, and review articles that focus on understanding the friction and wear behavior of components fabricated via hybrid/additive manufacturing of metals, polymers, ceramics, and composite materials.

Dr. Sougata Roy
Dr. Avik Samanta
Guest Editors

Manuscript Submission Information

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Keywords

  • tribology
  • hybrid manufacturing
  • wear behavior
  • friction performance
  • surface engineering
  • contact mechanics

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Published Papers (1 paper)

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Research

26 pages, 10090 KiB  
Article
Wear Resistance of Additively Manufactured Footwear Soles
by Shuo Xu, Shuvodeep De, Meysam Khaleghian and Anahita Emami
Lubricants 2025, 13(2), 89; https://doi.org/10.3390/lubricants13020089 - 17 Feb 2025
Viewed by 946
Abstract
This study systematically evaluated the wear resistance and mechanical performance of 3D-printed thermoplastic rubber (TPR) and flexible stereolithography (SLA) resin materials for footwear outsoles. Abrasion tests were conducted on 26 samples (2 materials × 13 geometries) to analyze the weight loss, variations in [...] Read more.
This study systematically evaluated the wear resistance and mechanical performance of 3D-printed thermoplastic rubber (TPR) and flexible stereolithography (SLA) resin materials for footwear outsoles. Abrasion tests were conducted on 26 samples (2 materials × 13 geometries) to analyze the weight loss, variations in the friction coefficient, temperature change, and deformation behavior. Finite element method (FEM) simulations incorporating the Ogden hyperelastic model were employed to investigate the stress distribution and wear patterns. The results revealed that TPR exhibits superior abrasion resistance and stable wear curves, making it suitable for high-load applications. On average, the TPR samples showed 27.3% lower weight loss compared to the SLA resin samples. The SLA resin samples exhibited a 65% higher mean coefficient of friction (COF) compared to the TPR samples. Furthermore, the SLA resin samples demonstrated a 94% higher temperature change during the sliding tests, reflecting greater friction-induced heating. The FEM simulations further validated TPR’s performance in high-stress regions and SLA resin’s deformation characteristics. This study’s findings not only highlight the performance differences between these two 3D-printed materials but also provide theoretical guidance for material selection based on wear behavior, contributing to the optimization of outsole design and its practical applications. Full article
(This article belongs to the Special Issue Wear and Friction in Hybrid and Additive Manufacturing Processes)
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