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Lubricants
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Advanced Surface Treatments and Coatings for Friction and Wear Reduction
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Advanced Surface Treatments and Coatings for Friction and Wear Reduction

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

Deadline for manuscript submissions: closed (1 November 2025) | Viewed by 5642

Special Issue Editor

Dr. Silvia Vesco

E-Mail Website
Guest Editor
Department of Enterprise Engineering “Mario Lucertini”, University of Rome Tor Vergata, 00133 Rome, Italy
Interests: engineered polymeric coatings; graphene coatings; electrodeposition; additive manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In recent years, advanced surface treatments and innovative coatings have been utilized in order to reduce friction and wear in a wide range of industrial applications. Techniques such as chemical vapor deposition, physical vapor deposition, plasma spray, and laser treatments have been adopted to improve the surface properties of materials, enhancing their wear resistance and reducing the energy losses caused by friction.

The application of nanostructured, composite, or hybrid coatings has significantly enhanced tribological performances, particularly under high-temperature and load conditions. Therefore, this Special Issue, entitled ‘Advanced Surface Treatments and Coatings for Friction and Wear Reduction’, provides an up-to-date overview of recent innovations in the field of surface treatments and coatings, exploring both experimental and simulative approaches to enhancing the tribological properties of advanced engineering materials in industrial applications.

The scope of this Special Issue includes, but is not limited to, the following topics:

  • Experimental applications of advanced surface treatments and coatings for friction and wear reduction;
  • Theoretical and computational studies on the interaction mechanisms between coatings and counterparts under normal loading;
  • The development of nanostructured and hybrid coatings with superior wear resistance properties and a low coefficient of friction;
  • The advanced application of tribological coatings in sectors such as automotive, aerospace and machine tools;
  • Improved lifetime in severe wear conditions and reduced environmental impact;
  • Advanced surface treatments for an improved component–lubricant interface.

This Special Issue is a perfect opportunity for researchers to provide the scientific community with an overview of recent advances and applications related to surface treatments and coatings for an enhanced tribological performance.

Dr. Silvia Vesco
Guest Editor

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 250 words) can be sent to the Editorial Office for assessment.

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

  • graphene
  • tribology
  • laser texturing
  • wear
  • coating
  • friction
  • fea
  • plasma treatment
  • thin film

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Published Papers (6 papers)

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Research

Jump to: Review

18 pages, 7540 KB  
Article
Effect of Treatment Time on the Tribological Behavior of Thermally Oxidized Ti-6Al-4V Under Dry and Oil-Lubricated Conditions
by Mohammed Al-Shan, Richard Bailey and Yong Sun
Lubricants 2025, 13(12), 528; https://doi.org/10.3390/lubricants13120528 - 3 Dec 2025
Viewed by 293
Abstract
Ti-6Al-4V alloy is a popular metal in engineering, utilized in aerospace and automotive industries because of its mechanical properties. However, Ti-6Al-4V’s poor tribological characteristics cause it to be susceptible to wear due to its low surface hardness and inadequate lubricity. In this study, [...] Read more.
Ti-6Al-4V alloy is a popular metal in engineering, utilized in aerospace and automotive industries because of its mechanical properties. However, Ti-6Al-4V’s poor tribological characteristics cause it to be susceptible to wear due to its low surface hardness and inadequate lubricity. In this study, thermal oxidation (TO) was performed on Ti-6Al-4V under specific conditions of 625 °C for various oxidation durations of 0.5, 1.5, 6, 24 and 96 h and the microstructure, friction, and wear behavior of TO-treated Ti-6Al-4V under dry and oil-lubricated sliding conditions were investigated. Characterization by XRD, SEM, and EDX confirms the development of oxide layers (OL) and oxygen diffusion zones (ODZ) of varying thicknesses. Tribological tests were conducted using a ball-on-disk configuration under a 5 N load against an Al2O3 counterface in both dry and 10W-40 oil-lubricated environments. Under dry conditions, extended oxidation times lead to a deterioration in friction and wear performance due to the increased brittleness and decreased adhesion of the thick OL, leading to brittle failure and interfacial delamination. In contrast, under oil lubrication conditions, all oxidized samples show stable, low-friction (~0.06) and minimal wear, dominated by boundary lubrication. The best performance is achieved at short oxidation durations, where a thin OL and a stable ODZ provide strong adhesion of the OL and high surface hardness. Wear rates up to three orders of magnitude lower than untreated Ti-6Al-4V are observed for short oxidation durations, where oxygen diffusion rather than thick oxide formation dominates the surface-hardening effect. SEM and EDX analyses confirmed the lack of tribofilms or additive-derived elements on the sliding surfaces, indicating that the improved performance results from the oxygen-enrichment in the subsurface and stable boundary lubrication, rather than chemical interactions with oil additives. Overall, oxidation duration is therefore essential to balance oxide growth and OL adhesion, ensuring superior lubricated wear resistance for titanium components. Full article
(This article belongs to the Special Issue Advanced Surface Treatments and Coatings for Friction and Wear Reduction)
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24 pages, 19579 KB  
Article
Biomimetic Hexagonal Texture with Dual-Orientation Groove Interconnectivity Enhances Lubrication and Tribological Performance of Gear Tooth Surfaces
by Yan Wang, Shanming Luo, Tongwang Gao, Jingyu Mo, Dongfei Wang and Xuefeng Chang
Lubricants 2025, 13(9), 420; https://doi.org/10.3390/lubricants13090420 - 18 Sep 2025
Cited by 1 | Viewed by 666
Abstract
Enhanced lubrication is critical for improving gear wear resistance. Current research on surface textures has overlooked the fundamental role of structural connectivity. Inspired by biological scales, a biomimetic hexagonal texture (BHT) was innovatively designed for tooth flanks, featuring dual-orientation grooves (perpendicular and inclined [...] Read more.
Enhanced lubrication is critical for improving gear wear resistance. Current research on surface textures has overlooked the fundamental role of structural connectivity. Inspired by biological scales, a biomimetic hexagonal texture (BHT) was innovatively designed for tooth flanks, featuring dual-orientation grooves (perpendicular and inclined to the rolling-sliding direction) with bidirectional interconnectivity. This design synergistically combines hydrodynamic effects and directional lubrication to achieve tribological breakthroughs. A lubrication model for line contact conditions was established. Subsequently, the texture parameters were then optimized using response surface methodology and numerical simulations. FZG gear tests demonstrated the superior performance of the optimized BHT, which achieved a substantial 82.83% reduction in the average wear area ratio and a 25.35% decrease in tooth profile deviation variation. This indicated that the biomimetic texture can effectively mitigate tooth surface wear, thereby extending the service life of gears. Furthermore, it significantly improves thermal management by enhancing convective heat transfer and lubricant distribution, as evidenced by a 7–11 °C rise in bulk lubricant temperature. This work elucidates the dual-mechanism coupling effect of bio-inspired textures in tribological enhancement, thus establishing a new paradigm for gear surface engineering. Full article
(This article belongs to the Special Issue Advanced Surface Treatments and Coatings for Friction and Wear Reduction)
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17 pages, 13580 KB  
Article
Investigation of the Lubrication Performance of Petal-Shaped Micro-Pit Texture on the Surface of Stator Rubber in Screw Pumps
by Xiaoming Wu, Xinfu Liu, Guoqing Han, Xiangzhi Shi, Jiuquan An, Xiaoli Yin and Li Geng
Lubricants 2025, 13(9), 379; https://doi.org/10.3390/lubricants13090379 - 26 Aug 2025
Viewed by 864
Abstract
This study proposed a surface modification method, based on petal-shaped micro-pit texture, allowing to solve the problem of significant wear of the stator caused by the oil film rupture in the metal-rubber friction pair of the screw pump under complex conditions in the [...] Read more.
This study proposed a surface modification method, based on petal-shaped micro-pit texture, allowing to solve the problem of significant wear of the stator caused by the oil film rupture in the metal-rubber friction pair of the screw pump under complex conditions in the later stages of oilfield extraction. A geometric model of the petal-shaped micro-pit texture on the stator rubber surface and a mathematical model of the hydrodynamic lubrication flow field based on the Reynolds equation were developed. Computational Fluid Dynamics (CFD) simulations and friction tests were conducted to systematically study the influence of the medium flow direction, texture area ratio, and texture size on the lubrication performance. The obtained results showed that compared with the flow in the x-direction, the load-carrying capacity of the oil film was increased by more than 0.93% when the medium flowed in y-direction, and it reached its optimal value at an area of 10%. When the area ratio reached 60%, the interference effect of the flow field reduced the pressure by 6.98%. The increase of the size of the petals allowed to expand the positive pressure zone and increase the net load-carrying capacity. Furthermore, friction tests demonstrated that the friction coefficient was decreased with the increase of the texture size and increased with the increase of the texture area ratio. The petal-shaped micro-pit texture with size of 350 μm and an area ratio of 10% demonstrated the lowest friction coefficient and highest wear resistance. Full article
(This article belongs to the Special Issue Advanced Surface Treatments and Coatings for Friction and Wear Reduction)
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26 pages, 9313 KB  
Article
Investigating Resulting Surface Topography and Residual Stresses in Bending DC01 Sheet Under Tension Friction Test
by Krzysztof Szwajka, Tomasz Trzepieciński, Marek Szewczyk, Joanna Zielińska-Szwajka and Marek Barlak
Lubricants 2025, 13(6), 255; https://doi.org/10.3390/lubricants13060255 - 9 Jun 2025
Cited by 2 | Viewed by 831
Abstract
This article presents the results of experimental studies aimed at determining the values of residual stresses and coefficient of friction (CoF) in bending under tension friction test, which simulates friction conditions in sheet metal forming. The influence of surface modification of the countersample [...] Read more.
This article presents the results of experimental studies aimed at determining the values of residual stresses and coefficient of friction (CoF) in bending under tension friction test, which simulates friction conditions in sheet metal forming. The influence of surface modification of the countersample and CoFs between the countersample and DC01 steel sheet on the residual stress were analysed. This study also focused on the influence of surface modification of countersamples on the change of the main parameters of DC01 steel sheets. The hole-drilling method was used to determine residual stresses. Electron beam melting, lead-ion implantation and a combination of these two techniques were used to modify the surface layer of 145Cr6 steel countersamples. The maximum value of the CoF, about 0.31, was found for the electron beam melted countersample. As a result of the surface modification process, this countersample was characterised by the lowest value of average roughness, which directly influenced the increase in the real contact area. The occurrence of residual tensile stresses was observed near the surface layer of the sheet strip in contact with the countersample. With the increase of the considered depth of residual stress measurement, the residual tensile stresses were transformed into compressive residual stresses with a value between −75 and −50 MPa, depending on the type of friction pair. SEM analyses allowed us to identify two main friction mechanisms for all friction pairs: adhesion and abrasive wear. Full article
(This article belongs to the Special Issue Advanced Surface Treatments and Coatings for Friction and Wear Reduction)
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Review

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31 pages, 2622 KB  
Review
Review and Prospect of Research Status on Sliding Bearing Coatings
by Fengming Du, Zhen Guo, Renhao Mo, Wenqing Lin and Shuai Zhang
Lubricants 2025, 13(11), 493; https://doi.org/10.3390/lubricants13110493 - 12 Nov 2025
Viewed by 788
Abstract
With the advancement of industrial technology toward high speed, heavy load, precision, and automation, traditional sliding bearing materials have been unable to meet modern industrial demands. Surface coating technology, as an efficient surface modification method, has become a key means to enhance the [...] Read more.
With the advancement of industrial technology toward high speed, heavy load, precision, and automation, traditional sliding bearing materials have been unable to meet modern industrial demands. Surface coating technology, as an efficient surface modification method, has become a key means to enhance the tribological properties, wear resistance, corrosion resistance, and fatigue resistance of sliding bearings, thus extending their service life. This paper systematically reviews the research progress of coating technology for sliding bearings in the past, aiming to fill the gap in comprehensive summaries of multi-material systems and multi-process technologies in existing reviews. In terms of materials, it focuses on the performance characteristics and application scenarios of three major coating types—metal-based, ceramic-based, and polymer-based—clarifying their advantages and limitations. In terms of processes, it analyzes the technical characteristics of mainstream methods including electroplating, magnetron sputtering, and laser cladding, as well as their innovative applications in replacing traditional processes. Furthermore, this review summarizes the latest research results in coating performance evaluation, such as tribological testing via pin-on-disk testers and corrosion resistance analysis via salt spray tests. Finally, it discusses future development trends in new materials, new process applications, and environmental sustainability. This work is expected to provide a valuable reference for related research and engineering applications in the field of sliding bearing coatings. Full article
(This article belongs to the Special Issue Advanced Surface Treatments and Coatings for Friction and Wear Reduction)
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22 pages, 2805 KB  
Review
Recent Developments in Self-Lubricating Thin-Film Coatings Deposited by a Sputtering Technique: A Critical Review of Their Synthesis, Properties, and Applications
by Sunil Kumar Tiwari, Turali Narayana, Rashi Tyagi, Gaurav Pant and Piyush Chandra Verma
Lubricants 2025, 13(8), 372; https://doi.org/10.3390/lubricants13080372 - 21 Aug 2025
Cited by 2 | Viewed by 1412
Abstract
In response to the demand for advanced materials in extreme environments, researchers have developed a variety of bulk and thin-film materials. One of the best-known processes for altering the mechanical and tribological properties of materials is surface engineering techniques. These involve various approaches [...] Read more.
In response to the demand for advanced materials in extreme environments, researchers have developed a variety of bulk and thin-film materials. One of the best-known processes for altering the mechanical and tribological properties of materials is surface engineering techniques. These involve various approaches to synthesize thin-film coatings, along with post-deposition treatments. The need for self-lubricating materials in extreme situations such as high-temperature applications, cryogenic temperatures, and vacuum systems has attracted the attention of researchers. They have fabricated several types of thin films using CVD and PVD techniques to meet this demand. Among the various techniques used for fabricating self-lubricating coatings, sputtering stands out as a special one. It contributes to developing smooth, homogeneous, and crack-free dense microstructures, which further enhance the coatings’ properties. This review explains the need for self-lubricating materials and the different techniques used to synthesize them. It discusses and summarizes the concept of synthesizing various types of self-lubricating films. It shows the different types of self-lubricating material systems, like transition metal-based nitrides and carbides, diamond-like carbon-based materials, and so on. This work also reflects the governing factors like the deposition temperature, doping elements, thickness of the film, deposition pressure, gas flow rate, etc., that influence the deposition results and, consequently, the properties of the film, as well as their advanced applications in different areas. This work reflects the self-lubricating properties of different kinds of films exposed to various environments in terms of their coefficient of friction and wear rate, emphasizing how the friction coefficient affects the wear rate. Full article
(This article belongs to the Special Issue Advanced Surface Treatments and Coatings for Friction and Wear Reduction)
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