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Lubricants
Special Issues
Wear and Friction in Hybrid and Additive Manufacturing Processes
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Wear and Friction in Hybrid and Additive Manufacturing Processes

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

Deadline for manuscript submissions: closed (30 June 2025) | Viewed by 2406

Special Issue Editors

Dr. Sougata Roy

E-Mail Website
Guest Editor
Department of Mechanical Engineering, Iowa State University, Ames, IA 50011, USA
Interests: additive manufacturing; tribology; surface engineering; failure analyses
Special Issues, Collections and Topics in MDPI journals
Dr. Avik Samanta

E-Mail Website
Guest Editor
Department of Mechanical Engineering, University of South Florida, Tampa, FL 33620, USA
Interests: laser material processing; laser-based wettability modification; laser shock processing
Special Issues, Collections and Topics in MDPI journals

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

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

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

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Published Papers (2 papers)

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Research

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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
Cited by 1 | Viewed by 1252
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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Review

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45 pages, 1648 KiB  
Review
Tribological Performance Enhancement in FDM and SLA Additive Manufacturing: Materials, Mechanisms, Surface Engineering, and Hybrid Strategies—A Holistic Review
by Raja Subramani, Ronit Rosario Leon, Rajeswari Nageswaren, Maher Ali Rusho and Karthik Venkitaraman Shankar
Lubricants 2025, 13(7), 298; https://doi.org/10.3390/lubricants13070298 - 7 Jul 2025
Viewed by 607
Abstract
Additive Manufacturing (AM) techniques, such as Fused Deposition Modeling (FDM) and Stereolithography (SLA), are increasingly adopted in various high-demand sectors, including the aerospace, biomedical engineering, and automotive industries, due to their design flexibility and material adaptability. However, the tribological performance and surface integrity [...] Read more.
Additive Manufacturing (AM) techniques, such as Fused Deposition Modeling (FDM) and Stereolithography (SLA), are increasingly adopted in various high-demand sectors, including the aerospace, biomedical engineering, and automotive industries, due to their design flexibility and material adaptability. However, the tribological performance and surface integrity of parts manufactured by AM are the biggest functional deployment challenges, especially in wear susceptibility or load-carrying applications. The current review provides a comprehensive overview of the tribological challenges and surface engineering solutions inherent in FDM and SLA processes. The overview begins with a comparative overview of material systems, process mechanics, and failure modes, highlighting prevalent wear mechanisms, such as abrasion, adhesion, fatigue, and delamination. The effect of influential factors (layer thickness, raster direction, infill density, resin curing) on wear behavior and surface integrity is critically evaluated. Novel post-processing techniques, such as vapor smoothing, thermal annealing, laser polishing, and thin-film coating, are discussed for their potential to endow surface durability and reduce friction coefficients. Hybrid manufacturing potential, where subtractive operations (e.g., rolling, peening) are integrated with AM, is highlighted as a path to functionally graded, high-performance surfaces. Further, the review highlights the growing use of finite element modeling, digital twins, and machine learning algorithms for predictive control of tribological performance at AM parts. Through material-level innovations, process optimization, and surface treatment techniques integration, the article provides actionable guidelines for researchers and engineers aiming at performance improvement of FDM and SLA-manufactured parts. Future directions, such as smart tribological, sustainable materials, and AI-based process design, are highlighted to drive the transition of AM from prototyping to end-use applications in high-demand industries. Full article
(This article belongs to the Special Issue Wear and Friction in Hybrid and Additive Manufacturing Processes)
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