Lubricants

23 pages, 5107 KiB

Open AccessArticle

Linear Rolling Guide Surface Wear-State Identification Based on Multi-Scale Fuzzy Entropy and Random Forest

by Conghui Nie, Changguang Zhou, Tieqiang Wang, Xiaoyi Wang, Huaxi Zhou and Hutian Feng

Lubricants 2025, 13(8), 323; https://doi.org/10.3390/lubricants13080323 - 24 Jul 2025

As a critical precision transmission element in numerical control (NC) machines, the linear rolling guide (LRG) suffers from surface wear degradation, which significantly impairs machining accuracy and operational reliability. Despite its importance, effective identification methods for LRG degradation remain limited. In this study, [...] Read more.

As a critical precision transmission element in numerical control (NC) machines, the linear rolling guide (LRG) suffers from surface wear degradation, which significantly impairs machining accuracy and operational reliability. Despite its importance, effective identification methods for LRG degradation remain limited. In this study, a hybrid approach combining multi-scale fuzzy entropy (MFE) with a gray wolf-optimized random forest (GWO-RF) algorithm was proposed to identify the surface wear state of the LRG. Preload degradation and vibration signals were collected at three surface wear stages throughout the LGR’s service life. The vibration signals were decomposed and reconstructed using complete ensemble empirical mode decomposition with adaptive noise (CEEMDAN), followed by multi-scale fuzzy entropy analysis of the reconstructed signals. After dimensionality reduction via kernel principal component analysis (KPCA), the processed features were fed into the GWO-RF model for classification. Experimental results demonstrated a recognition accuracy of 97.9%. Full article

(This article belongs to the Special Issue High Performance Machining and Surface Tribology)

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43 pages, 16361 KiB

Open AccessReview

Progress on Sustainable Cryogenic Machining of Hard-to-Cut Material and Greener Processing Techniques: A Combined Machinability and Sustainability Perspective

by Shafahat Ali, Said Abdallah, Salman Pervaiz and Ibrahim Deiab

Lubricants 2025, 13(8), 322; https://doi.org/10.3390/lubricants13080322 - 23 Jul 2025

Abstract

The current research trends of production engineering are based on optimizing the machining process concerning human and environmental factors. High-performance materials, such as hardened steels, nickel-based alloys, fiber-reinforced polymer (FRP) composites, and titanium alloys, are classified as hard-to-cut due to their ability to [...] Read more.

The current research trends of production engineering are based on optimizing the machining process concerning human and environmental factors. High-performance materials, such as hardened steels, nickel-based alloys, fiber-reinforced polymer (FRP) composites, and titanium alloys, are classified as hard-to-cut due to their ability to maintain strength at high operating temperatures. Due to these characteristics, such materials are employed in applications such as aerospace, marine, energy generation, and structural. The purpose of this article is to investigate the machinability of these alloys under various cutting conditions. The purpose of this article is to compare cryogenic cooling and cryogenic processing from the perspective of machinability and sustainability in the manufacturing process. Compared to conventional machining, hybrid techniques, which mix cryogenic and minimal quantity lubricant, led to significantly reduced cutting forces of 40–50%, cutting temperatures and surface finishes by approximately 20–30% and more than 40%, respectively. A carbon footprint is determined by several factors including power consumption, energy requirements, and carbon dioxide emissions. As a result of the cryogenic technology, the energy consumption, power consumption, and CO₂ emissions were reduced by 40%, 28%, and 35%. Full article

(This article belongs to the Special Issue Minimum Quantity Lubrication (MQL): Advances, Applications, and Future Perspectives)

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18 pages, 4335 KiB

Open AccessArticle

DEM Study on the Impact of Liner Lifter Bars on SAG Mill Collision Energy

by Yong Wang, Qingfei Xiao, Saizhen Jin, Mengtao Wang, Ruitao Liu and Guobin Wang

Lubricants 2025, 13(8), 321; https://doi.org/10.3390/lubricants13080321 - 23 Jul 2025

Abstract

The semi-autogenous grinding (SAG) mill, renowned for its high efficiency, high production capacity, and low cost, is widely used for crushing and grinding equipment. However, the current understanding of the overall particle behavior influencing its efficiency remains relatively limited, particularly the impact of [...] Read more.

The semi-autogenous grinding (SAG) mill, renowned for its high efficiency, high production capacity, and low cost, is widely used for crushing and grinding equipment. However, the current understanding of the overall particle behavior influencing its efficiency remains relatively limited, particularly the impact of the shape of SAG mill liners on material behavior. This study employs discrete element method (DEM) simulation technology to investigate the effects of different liner structures on particle trajectories and collision energy, systematically investigating the impact of lifter bars angle, height, and the number of lifter bars on grinding efficiency. The results of single-factor simulations indicate that when the lifter bars height (230 mm) and the number of lifter bars (36) are fixed, the total collision energy dissipation between steel balls and ore, as well as among ore particles, reaches a maximum of 526,069.53 J when the lifter bars angle is 25°. When the lifter bar angle is fixed at 25° and the number of lifter bars is set to 36, the maximum collision energy dissipation of 627,606.06 J occurs at a lifter bars height of 210 mm. When the angle (25°) and height (210 mm) are fixed, the highest energy dissipation of 443,915.37 J is observed with 12 lifter bars. Results from the three-factor, three-level orthogonal experiment reveal that the number of lifter bars exerts the most significant influence on grinding efficiency, followed by the angle and height. The optimal combination is determined to be a 20° angle, 12 lifter bars, and a 210 mm height, resulting in the highest total collision energy dissipation of 700,334 J. This represents an increase of 379,466 J compared to the original SAG mill liner configuration (320,868 J). This research aims to accurately simulate the motion of discrete particles within the mill through DEM simulations, providing a basis for optimizing the operational parameters and structural design of SAG mills. Full article

(This article belongs to the Special Issue Tribology in Ball Milling: Theory and Applications)

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25 pages, 3515 KiB

Open AccessArticle

Optimizing Sustainable Machining Conditions for Incoloy 800HT Using Twin-Nozzle MQL with Bio-Based Groundnut Oil Lubrication

by Ramai Ranjan Panigrahi, Ramanuj Kumar, Ashok Kumar Sahoo and Amlana Panda

Lubricants 2025, 13(8), 320; https://doi.org/10.3390/lubricants13080320 - 23 Jul 2025

Abstract

This study explores the machinability of Incoloy 800HT (high temperature) under a sustainable lubrication approach, employing a twin-nozzle minimum quantity lubrication (MQL) system with groundnut oil as a green cutting fluid. The evaluation focuses on key performance indicators, including surface roughness, tool flank [...] Read more.

This study explores the machinability of Incoloy 800HT (high temperature) under a sustainable lubrication approach, employing a twin-nozzle minimum quantity lubrication (MQL) system with groundnut oil as a green cutting fluid. The evaluation focuses on key performance indicators, including surface roughness, tool flank wear, power consumption, carbon emissions, and chip morphology. Groundnut oil, a biodegradable and nontoxic lubricant, was chosen to enhance environmental compatibility while maintaining effective cutting performance. The Taguchi L₁₆ orthogonal array (three factors and four levels) was utilized to conduct experimental trials to analyze machining characteristics. The best surface quality (surface roughness, Ra = 0.514 µm) was obtained at the lowest depth of cut (0.2 mm), modest feed (0.1 mm/rev), and moderate cutting speed (160 m/min). The higher ranges of flank wear are found under higher cutting speed conditions (320 and 240 m/min), while lower wear values (<0.09 mm) were observed under lower speed conditions (80 and 160 m/min). An entropy-integrated multi-response optimization using the MOORA (multi-objective optimization based on ratio analysis) method was employed to identify optimal machining parameters, considering the trade-offs among multiple conflicting objectives. The entropy method was used to assign weights to each response. The obtained optimal conditions are as follows: cutting speed = 160 m/min, feed = 0.1 mm/rev, and depth of cut = 0.2 mm. Optimized outcomes suggest that this green machining strategy offers a viable alternative for sustainable manufacturing of difficult-to-machine alloys like Incoloy 800 HT. Full article

(This article belongs to the Special Issue Minimum Quantity Lubrication (MQL): Advances, Applications, and Future Perspectives)

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18 pages, 6673 KiB

Open AccessArticle

Tribological Properties of MoN/TiN Multilayer Coatings Prepared via High-Power Impulse Magnetron Sputtering

by Jiaming Xu, Ping Zhang, Jianjian Yu, Puyou Ying, Tao Yang, Jianbo Wu, Tianle Wang, Nikolai Myshkin and Vladimir Levchenko

Lubricants 2025, 13(8), 319; https://doi.org/10.3390/lubricants13080319 - 22 Jul 2025

Abstract

To address the limitations of single-layer nitride coatings, such as poor load adaptability and low long-term durability, MoN/TiN multilayer coatings were prepared via high-power impulse magnetron sputtering (HiPIMS). HiPIMS produces highly ionized plasmas that enable intense ion bombardment, yielding nitride films with enhanced [...] Read more.

To address the limitations of single-layer nitride coatings, such as poor load adaptability and low long-term durability, MoN/TiN multilayer coatings were prepared via high-power impulse magnetron sputtering (HiPIMS). HiPIMS produces highly ionized plasmas that enable intense ion bombardment, yielding nitride films with enhanced mechanical strength, durability, and thermal stability versus conventional methods. The multilayer coating demonstrated a low coefficient of friction (COF, ~0.4) and wear rate (1.31 × 10⁻⁷ mm³/[N·m]). In contrast, both TiN and MoN coatings failed at 5 N and 10 N loads, respectively. Under increasing loads, the multilayer coating maintained stable wear rates (1.84–3.06 × 10⁻⁷ mm³/[N·m]) below 20 N, and ultimately failed at 25 N. Furthermore, the MoN layer contributes to COF reduction. Grazing-incidence X-ray diffraction analysis confirmed the enhanced crystallographic stability of the multilayer coating, thereby revealing a dominant (111) orientation. The multilayer architecture suppresses crack propagation while effectively balancing hardness and toughness, offering a promising design for extreme-load applications. Full article

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15 pages, 4083 KiB

Open AccessArticle

Tribological and Corrosion Effects from Electrodeposited Ni-hBN over SS304 Substrate

by Suresh Velayudham, Elango Natarajan, Kalaimani Markandan, Kaviarasan Varadaraju, Santhosh Mozhuguan Sekar, Gérald Franz and Anil Chouhan

Lubricants 2025, 13(7), 318; https://doi.org/10.3390/lubricants13070318 - 21 Jul 2025

Abstract

The aim of the present study is to investigate the influence of Nickel–Hexagonal Boron Nitride (Ni-hBN) nanocomposite coatings, deposited using the pulse reverse current electrodeposition technique. This experimental study focuses on assessing the tribological and corrosion properties of the produced coatings on the [...] Read more.

The aim of the present study is to investigate the influence of Nickel–Hexagonal Boron Nitride (Ni-hBN) nanocomposite coatings, deposited using the pulse reverse current electrodeposition technique. This experimental study focuses on assessing the tribological and corrosion properties of the produced coatings on the SS304 substrate. The microhardness of the as-deposited (AD) sample and heat-treated (HT) sample were 49% and 83.8% higher compared to the control sample. The HT sample exhibited a grain size which was approximately 9.7% larger than the AD sample owing to the expansion–contraction mechanism of grains during heat treatment and sudden quenching. Surface roughness reduced after coating, where the Ni-hBN-coated sample measured a roughness of 0.43 µm compared to 0.48 µm for the bare surface. The average coefficient of friction for the AD sample was 42.4% lower than the bare surface owing to the self-lubricating properties of nano hBN. In particular, the corrosion rate of the AD sample was found to be 0.062 mm/year, which was lower than values reported in other studies. As such, findings from the present study can be particularly beneficial for applications in the automotive and aerospace industries, where enhanced wear resistance, reduced friction, and superior corrosion protection are critical for components such as engine parts, gears, bearings and shafts. Full article

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16 pages, 5442 KiB

Open AccessCommunication

Analysis of the Impact of Frog Wear on the Wheel–Rail Dynamic Performance in Turnout Zones of Urban Rail Transit Lines

by Yanlei Li, Dongliang Zeng, Xiuqi Wei, Xiaoyu Hu and Kaiyun Wang

Lubricants 2025, 13(7), 317; https://doi.org/10.3390/lubricants13070317 - 20 Jul 2025

Abstract

To investigate how severe wear at No. 12 turnout frogs in an urban rail transit line operating at speeds over 120 km/h on the dynamic performance of the vehicle, a vehicle–frog coupled dynamic model was established by employing the 2021 version of SIMPACK [...] Read more.

To investigate how severe wear at No. 12 turnout frogs in an urban rail transit line operating at speeds over 120 km/h on the dynamic performance of the vehicle, a vehicle–frog coupled dynamic model was established by employing the 2021 version of SIMPACK software. Profiles of No. 12 alloy steel frogs and metro wheel rims were measured to simulate wheel–rail interactions as the vehicle traverses the turnout, using both brand-new and worn frog conditions. The experimental results indicate that increased service life deepens frog wear, raises equivalent conicity, and intensifies wheel–rail forces. When a vehicle passes through the frog serviced for over 17 months at the speed of 120 km/h, the maximum derailment coefficient, lateral acceleration of the car body, and lateral and vertical wheel–rail forces increased by 0.14, 0.17 m/s², 9.52 kN, and 105.76 kN, respectively. The maximum contact patch area grew by 35.73%, while peak contact pressure rose by 236 MPa. To prevent dynamic indicators from exceeding safety thresholds and ensure train operational safety, it is recommended that the frog maintenance cycle be limited to 12 to 16 months. Full article

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24 pages, 15762 KiB

Open AccessArticle

Performance of TiSiN/TiAlN-Coated Carbide Tools in Slot Milling of Hastelloy C276 with Various Cooling Strategies

by Ly Chanh Trung and Tran Thien Phuc

Lubricants 2025, 13(7), 316; https://doi.org/10.3390/lubricants13070316 - 19 Jul 2025

Abstract

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to [...] Read more.

Nickel-based superalloy Hastelloy C276 is widely used in high-performance industries due to its strength, corrosion resistance, and thermal stability. However, these same properties pose substantial challenges in machining, resulting in high tool wear, surface defects, and dimensional inaccuracies. This study investigates methods to enhance machining performance and surface quality by evaluating the tribological behavior of TiSiN/TiAlN-coated carbide inserts under six cooling and lubrication conditions: dry, MQL with coconut oil, Cryo-LN₂, Cryo-LCO₂, MQL–Cryo-LN₂, and MQL–Cryo-LCO₂. Open-slot finishing was performed at constant cutting parameters, and key indicators such as cutting zone temperature, tool wear, surface roughness, chip morphology, and microhardness were analyzed. The hybrid MQL–Cryo-LN₂ approach significantly outperformed other methods, reducing cutting zone temperature, tool wear, and surface roughness by 116.4%, 94.34%, and 76.11%, respectively, compared to dry machining. SEM and EDS analyses confirmed abrasive, oxidative, and adhesive wear as the dominant mechanisms. The MQL–Cryo-LN₂ strategy also lowered microhardness, in contrast to a 39.7% increase observed under dry conditions. These findings highlight the superior performance of hybrid MQL–Cryo-LN₂ in improving machinability, offering a promising solution for precision-driven applications. Full article

(This article belongs to the Special Issue High Performance Machining and Surface Tribology)

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22 pages, 6390 KiB

Open AccessArticle

Exploring the Tribological Potential of Y₂BaCuO₅ Precursor Powders as a Novel Lubricant Additive

by Shuo Cheng, Longgui He and Jimin Xu

Lubricants 2025, 13(7), 315; https://doi.org/10.3390/lubricants13070315 - 19 Jul 2025

Abstract

Friction leads to substantial energy losses and wear in mechanical systems. This study explores the tribological potential of the high-temperature superconductor precursor Y₂BaCuO₅ (Y211), synthesized via chemical co-precipitation, as a novel additive to PAO6 base oil. A 0.3 wt.% Y211/PAO6 [...] Read more.

Friction leads to substantial energy losses and wear in mechanical systems. This study explores the tribological potential of the high-temperature superconductor precursor Y₂BaCuO₅ (Y211), synthesized via chemical co-precipitation, as a novel additive to PAO6 base oil. A 0.3 wt.% Y211/PAO6 lubricant (CD) was formulated using ultrasonic dispersion. Tribological performance was evaluated using a custom end-face tribometer (steel-on-iron) under varying loads (100–500 N) and speeds (300–500 rpm), comparing CD to neat PAO6. The results indicate that the Y211 additive consistently reduced the coefficient of friction (COF) relative to neat PAO6, maintaining a stable value around ~0.1. However, its effectiveness was strongly load-dependent: a significant friction reduction was observed at 100 N, while the benefit diminished at higher loads (>200 N), with the COF peaking around 200 N. Rotational speed exerted minimal influence. Compared with neat PAO6, the inclusion of 0.3 wt.% Y211 resulted in a reduction in the coefficient of friction by approximately 50% under low-load conditions (100 N), with COF values decreasing from 0.1 to 0.045. Wear depth measurements also revealed a reduction of over 30%, supporting the additive’s anti-wear efficacy. Y211 demonstrates potential as a friction-reducing additive, particularly under low loads, but its high-load performance limitations warrant further optimization and mechanistic studies. This highlights a novel tribological application for Y211. The objective of this study is to evaluate the tribological effectiveness of Y₂BaCuO₅ (Y211) as a lubricant additive, investigate its load-dependent friction behavior, and explore its feasibility as a multifunctional additive leveraging its superconductive precursor structure. Full article

(This article belongs to the Special Issue Novel Lubricant Additives in 2025)

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26 pages, 10071 KiB

Open AccessArticle

Mechanisms of Adhesion Increase in Wet Sanded Wheel–Rail Contacts—A DEM-Based Analysis

by Bettina Suhr, William A. Skipper, Roger Lewis and Klaus Six

Lubricants 2025, 13(7), 314; https://doi.org/10.3390/lubricants13070314 - 18 Jul 2025

Abstract

In railways, problems in braking and traction can be caused by so-called low-adhesion conditions. Adhesion is increased by sanding, where sand grains are blasted towards the wheel–rail contact. Despite the successful use of sanding in practice and extensive experimental studies, the physical mechanisms [...] Read more.

In railways, problems in braking and traction can be caused by so-called low-adhesion conditions. Adhesion is increased by sanding, where sand grains are blasted towards the wheel–rail contact. Despite the successful use of sanding in practice and extensive experimental studies, the physical mechanisms of adhesion increase are poorly understood. This study combines experimental work with a DEM model to aim at a deeper understanding of adhesion increase during sanding. The experimentally observed processes during sanding involve repeated grain breakage, varying sand fragment spread, formation of clusters of crushed sand powders, plastic deformation of the steel surfaces due to the high load applied and shearing of the compressed sand fragments. The developed DEM model includes all these processes. Two types of rail sand are analysed, which differ in adhesion increase in High-Pressure Torsion tests under wet contact conditions. This study shows that higher adhesion is achieved when a larger proportion of the normal load is transferred through sand–steel contacts. This is strongly influenced by the coefficient of friction between sand and steel. Adhesion is higher for larger sand grains, higher sand fragment spread, and higher steel hardness, resulting in less indentation, all leading to larger areas covered by sand. Full article

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16 pages, 6100 KiB

Open AccessArticle

Investigation of the Friction and Wear Behavior of Cr-Mo-V Steel with Different Surface Treatment Processes

by Wei Zhang, Jian Zhang, Shizhong Wei, Liuliang Chen, Wei Zhang, Zhenhuan Sun, Chong Chen, Feng Mao, Xiaodong Wang, Caihong Dou and Cheng Zhang

Lubricants 2025, 13(7), 313; https://doi.org/10.3390/lubricants13070313 - 18 Jul 2025

Abstract

Hot work die steel is an alloy steel with good high-temperature performance, which is widely used in mechanical manufacturing, aerospace, and other fields. During the working process of hot working mold steel, it is subjected to high temperature, wear, and other effects, which [...] Read more.

Hot work die steel is an alloy steel with good high-temperature performance, which is widely used in mechanical manufacturing, aerospace, and other fields. During the working process of hot working mold steel, it is subjected to high temperature, wear, and other effects, which can lead to a decrease in the surface hardness of the mold, accelerate surface damage, shorten the service life, and reduce the quality of the workpiece. In order to improve the wear resistance of the mold, this paper conducts two surface treatments, chrome plating and nitriding, on the surface of hot work mold steel, and compares the high-temperature wear behavior of the materials after the two surface treatments. The results indicate that the hot work die steel obtained higher surface hardness and wear resistance after nitriding surface modification. After nitriding treatment, the surface of hot work die steel contains ε phase (Fe_2–3N), which improves its surface hardness and wear resistance, thus exhibiting better surface hardness and wear resistance than the chrome-plated sample. In this study, the high-temperature wear behavior of hot work die steel after two kinds of surface strengthening treatments was deeply discussed, and the high-temperature wear mechanism of steel after surface strengthening was revealed. It provides a theoretical basis and experimental basis for the surface modification of hot working die steel, and also provides new ideas and methods for improving the service life and workpiece quality of hot working die steel in industrial production. In this study, the advantages and disadvantages of high-temperature wear resistance of hot working die steel after chromium plating and nitriding were systematically compared for the first time, which provided a scientific basis for the selection of surface strengthening technology of hot working die steel and had important academic value and practical application significance. Full article

(This article belongs to the Special Issue Wear-Resistant Coatings and Film Materials)

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18 pages, 4348 KiB

Open AccessArticle

Maskless Electrochemical Texturing (MECT) Applied to Skin-Pass Cold Rolling

by Paulo L. Monteiro, Jr., Wilian Labiapari, Washington M. Da Silva, Jr., Cristiano de Azevedo Celente and Henara Lillian Costa

Lubricants 2025, 13(7), 312; https://doi.org/10.3390/lubricants13070312 - 18 Jul 2025

Abstract

The surface topography of the rolls used in skin-pass cold rolling determines the surface finish of rolled sheets. In this sense, work rolls can be intentionally textured to produce certain topographical features on the final sheet surface. The maskless electrochemical texturing method (MECT) [...] Read more.

The surface topography of the rolls used in skin-pass cold rolling determines the surface finish of rolled sheets. In this sense, work rolls can be intentionally textured to produce certain topographical features on the final sheet surface. The maskless electrochemical texturing method (MECT) is a potential candidate for industrial-scale application due to its reduced texturing cost and time when compared to traditional texturing methods. However, there are few studies in the literature that address the MECT method applied to the topography control of cold rolling work rolls. The present work aims to analyze the viability of surface texturing via MECT of work rolls used in skin-pass cold rolling. In this study, we first investigated how texturing occurs for tool steel using flat textured samples to facilitate the understanding of the dissolution mechanisms involved. In this case, a specially designed texturing chamber was built to texture flat samples extracted from an actual work roll. The results indicated that the anodic dissolution involved in tool steel texturing occurs preferentially in the metallic matrix around the primary carbides. Then, we textured a work roll used in pilot-scale rolling tests, which required the development of a special prototype to texture cylindrical surfaces. After texturing, the texture transfer from the work roll to the sheets was investigated. Rolling tests showed that the work roll surface textured with a dimple pattern generated a pillar-shaped texture pattern on the sheet surface, possibly due to a reverse extrusion mechanism. Full article

(This article belongs to the Special Issue Recent Achievements and Future Developments in Surface Texture Control of Tribological Properties)

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17 pages, 3902 KiB

Open AccessArticle

Electrical Potential-Induced Lubricity Changes in an Ionic Liquid-Lubricated Friction Pair

by Raimondas Kreivaitis, Audrius Žunda and Albinas Andriušis

Lubricants 2025, 13(7), 311; https://doi.org/10.3390/lubricants13070311 - 17 Jul 2025

Abstract

The control of lubricity induced by electric potential is appealing for numerous applications. On the other hand, the high polarity of ionic liquids facilitates the adsorption of equally charged molecules onto polar surfaces. This phenomenon and its consequences are well understood at the [...] Read more.

The control of lubricity induced by electric potential is appealing for numerous applications. On the other hand, the high polarity of ionic liquids facilitates the adsorption of equally charged molecules onto polar surfaces. This phenomenon and its consequences are well understood at the nanoscale; however, they have recently garnered significant attention at the macroscale. This study investigates the lubricity of trihexyltetradecylphosphonium dicyanamide, a phosphonium ionic liquid, when used as a neat lubricant in reciprocating sliding under electrically charged conditions. Two different polarities with the same potential were applied to the friction pair of bearing steel against bearing steel while monitoring electrical contact resistance. The lubricity was evaluated through measurements of friction, wear, surface morphology, and composition. It was found that the application of electric potential significantly alters the lubricity of the investigated ionic liquid where a positive potential applied to the ball resulted in the least damaging situation. The recorded electrical contact resistance enabled the monitoring of tribofilm formation during reciprocation. It was found that there was minimal to no separation between interacting surfaces when the ball was changing direction. Full article

(This article belongs to the Special Issue Recent Advances in Eco-Friendly Ionic Liquids as Lubricants and Additives)

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17 pages, 4068 KiB

Open AccessArticle

Mechanical Properties and Tribological Behavior of Al₂O₃–ZrO₂ Ceramic Composites Reinforced with Carbides

by Jana Andrejovská, Dávid Medveď, Marek Vojtko, Richard Sedlák, Piotr Klimczyk and Ján Dusza

Lubricants 2025, 13(7), 310; https://doi.org/10.3390/lubricants13070310 - 17 Jul 2025

Abstract

To elucidate the key material parameters governing the tribological performance of ceramic composites under dry sliding against steel, this study presents a comprehensive comparative assessment of the microstructural characteristics, mechanical performance, and tribological behavior of two alumina–zirconia (Al₂O₃–ZrO₂ [...] Read more.

To elucidate the key material parameters governing the tribological performance of ceramic composites under dry sliding against steel, this study presents a comprehensive comparative assessment of the microstructural characteristics, mechanical performance, and tribological behavior of two alumina–zirconia (Al₂O₃–ZrO₂) ceramic composites, each reinforced with a 42 vol.% carbide phase: zirconium carbide (ZrC) and tungsten carbide (WC). Specifically, tungsten carbide (WC) was selected for its exceptional bulk mechanical properties, while zirconium carbide (ZrC) was chosen to contrast its potentially different interfacial reactivity against a steel counterface. ZrC and WC were selected as reinforcing phases due to their high hardness and distinct chemical and interfacial properties, which were expected to critically affect the wear and friction behavior of the composites under demanding conditions. Specimens were consolidated via spark plasma sintering (SPS). The investigation encompassed macro- and nanoscale hardness measurements (Vickers hardness HV₁, HV₁₀; nanoindentation hardness H), elastic modulus (E), fracture toughness (K_IC), coefficient of friction (COF), and specific wear rate (W_s) under unlubricated reciprocating sliding against 100Cr6 steel at normal loads of 10 N and 25 N. The Al₂O₃–ZrO₂–WC composite exhibited an ultrafine-grained microstructure and markedly enhanced mechanical properties (HV₁₀ ≈ 20.9 GPa; H ≈ 33.6 GPa; K_IC ≈ 4.7 MPa·m^½) relative to the coarse-grained Al₂O₃–ZrO₂–ZrC counterpart (HV₁₀ ≈ 16.6 GPa; H ≈ 27.0 GPa; K_IC ≈ 3.2 MPa·m^½). Paradoxically, the ZrC-reinforced composite demonstrated superior tribological performance, with a low and load-independent specific wear rate (W_s ≈ 1.2 × 10⁻⁹ mm³/Nm) and a stable steady-state COF of approximately 0.46. Conversely, the WC-reinforced system exhibited significantly elevated wear volumes—particularly under the 25 N regime—and a higher, more fluctuating COF. Scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM–EDX) of the wear tracks revealed the formation of a continuous, iron-enriched tribofilm on the ZrC composite, derived from counterface material transfer, whereas the WC composite surface displayed only sparse tribofilm development. These findings underscore that, in steel-paired tribological applications of Al₂O₃–ZrO₂–based composites, the efficacy of interfacial tribolayer generation can supersede intrinsic bulk mechanical attributes as the dominant factor governing wear resistance. Full article

(This article belongs to the Special Issue Tribological and Mechanical Characteristics of Aluminum Metal Matrix Composites and Their Applications)

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18 pages, 10294 KiB

Open AccessArticle

High-Precision Normal Stress Measurement Methods for Tire–Road Contact and Its Spatial and Frequency Domain Distribution Characteristics

by Liang Song, Xixian Wu, Zijie Xie, Jie Gao, Di Yun and Zongjian Lei

Lubricants 2025, 13(7), 309; https://doi.org/10.3390/lubricants13070309 - 16 Jul 2025

Abstract

This study investigates measurement methods for and the distribution characteristics of normal stress within tire–road contact areas. A novel measurement method, integrating 3D scanning technology with bearing area curve (BAC) analysis, is proposed. This method quantifies the rubber penetration depth and calculates contact [...] Read more.

This study investigates measurement methods for and the distribution characteristics of normal stress within tire–road contact areas. A novel measurement method, integrating 3D scanning technology with bearing area curve (BAC) analysis, is proposed. This method quantifies the rubber penetration depth and calculates contact stress based on rubber deformation. The key innovation of this method lies in this integrated methodology for high-precision stress mapping. In the spatial domain, stress distribution is characterized by the percentage of area occupied by different stress intervals, while in the frequency domain, stress levels are analyzed at various frequencies. The results demonstrate that as the Mean Profile Depth (MPD) of the road texture increases, the areas under stress greater than 1.0 MPa increase, while the areas under stress less than 0.8 MPa decrease. However, when the MPD exceeds 0.7 mm, this effect becomes less pronounced. Higher loads and harder rubber reduce the proportion of areas under lower stress and increase the proportion under higher stress. Low-frequency (<800 1/m) stress components increase with an MPD up to 0.7 mm, beyond which they exhibit diminished sensitivity. Stress at the same frequency is not significantly affected by load variation but increases markedly with increasing rubber hardness. This research provides crucial insights into contact stress distribution, establishing a foundation for analyzing road friction and optimizing surface texture design oriented towards high-friction pavements. Full article

(This article belongs to the Special Issue Tire/Road Interface and Road Surface Textures)

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23 pages, 11965 KiB

Open AccessArticle

Research on the Impact of Labyrinth Seal Ring Tooth Profile on the Pressure Pulsation of Leakage Chambers in High-Speed Centrifugal Pumps

by Guodong Zhao, Jiahao Xu, Jie Lian, Yanpi Lin and Zuchao Zhu

Lubricants 2025, 13(7), 308; https://doi.org/10.3390/lubricants13070308 - 16 Jul 2025

Abstract

The gap seal ring is a critical component in high-speed centrifugal pumps. The leakage rate and performance of the pump are sensitive to variation in seal ring parameters. This study investigates the influence of seal ring tooth profile on the leakage flow of [...] Read more.

The gap seal ring is a critical component in high-speed centrifugal pumps. The leakage rate and performance of the pump are sensitive to variation in seal ring parameters. This study investigates the influence of seal ring tooth profile on the leakage flow of pump chambers. Numerical simulation and experimental tests are used to analyze the impact of four different tooth-height labyrinth seal ring structures on the pressure pulsation characteristics of pump leakage chambers. It can be concluded that the use of labyrinth seal rings can significantly reduce the pressure pulsation and leakage rate of pump chambers. For the Case 2 structure with a tooth height of 0.18 mm, the pressure pulsation in the pump chamber can be reduced by a maximum of 22.5%, and the leakage rate can be reduced by 41.1%. For the Case 3 structure with a tooth height of 0.23 mm, the pressure pulsation in the pump chamber can be reduced by a maximum of 30.3%, and the leakage rate can be reduced by 40.6%. The use of labyrinth seal rings significantly reduces the pressure pulsation intensity of the impeller surfaces, which improves the force stability of the high-speed centrifugal pump impeller. This study is helpful in providing theoretical support for the design of labyrinth seal rings in high-speed centrifugal pumps. Full article

(This article belongs to the Special Issue Recent Advances in Sealing Technologies)

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24 pages, 10860 KiB

Open AccessArticle

Dynamic Characteristics of ‘Floating’ Valve Plate for Internal Curve Hydraulic Motor

by Wei Ma, Guolai Yang, Wenbin Cao, Shaohui Yao, Guixiang Bai, Chuanchuan Cao and Shoupeng Song

Lubricants 2025, 13(7), 307; https://doi.org/10.3390/lubricants13070307 - 15 Jul 2025

Abstract

The internal curve hydraulic motor valve plate has a clearance self-compensation performance that can effectively improve the working efficiency of the valve plate. However, the dynamic characteristics of the valve plates require further investigation. This study considers the self-compensating ‘floating’ valve plate as [...] Read more.

The internal curve hydraulic motor valve plate has a clearance self-compensation performance that can effectively improve the working efficiency of the valve plate. However, the dynamic characteristics of the valve plates require further investigation. This study considers the self-compensating ‘floating’ valve plate as the research object, proposes a dynamic characteristic analysis method for the internal curve hydraulic motor valve plate, and explores the changing rule of oil film thickness and surplus pressing force of the valve plate. The results showed that an increase in the inlet pressure and oil temperature led to an increase in the thickness of the oil film, and the amplitude of the oil film thickness was larger, whereas the rotational speed of the oil film thickness of the valve plate pair was not obvious. When the inlet pressure is lower than 8 MPa, and the oil temperature is in the range of 20–30 °C, the oil film is mainly subjected to the squeezing effect of the valve plate, and the displacement of the valve plate decreased with increasing rotational speed. The inlet pressure is the main factor affecting the displacement of the ‘floating’ valve plate, and when the inlet pressure reaches 8.7 MPa, the valve plate is in hydrostatic balance support. In addition, the surplus pressing force coefficient of the valve plate decreased with increasing inlet pressures. This study provides theoretical support for the design of variable pressing force valve plates for internal curve hydraulic motors by investigating the dynamic characteristics of “floating” valve plates. Full article

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22 pages, 11458 KiB

Open AccessArticle

Convolutional Neural Networks—Long Short-Term Memory—Attention: A Novel Model for Wear State Prediction Based on Oil Monitoring Data

by Ying Du, Hui Wei, Tao Shao, Shishuai Chen, Jianlei Wang, Chunguo Zhou and Yanchao Zhang

Lubricants 2025, 13(7), 306; https://doi.org/10.3390/lubricants13070306 - 15 Jul 2025

Abstract

Wear state prediction based on oil monitoring technology enables the early identification of potential wear and failure risks of friction pairs, facilitating optimized equipment maintenance and extended service life. However, the complexity of lubricating oil monitoring data often poses challenges in extracting discriminative [...] Read more.

Wear state prediction based on oil monitoring technology enables the early identification of potential wear and failure risks of friction pairs, facilitating optimized equipment maintenance and extended service life. However, the complexity of lubricating oil monitoring data often poses challenges in extracting discriminative features, limiting the accuracy of wear state prediction. To address this, a CNN–LSTM–Attention network is specially constructed for predicting wear state, which hierarchically integrates convolutional neural networks (CNNs) for spatial feature extraction, long short-term memory (LSTM) networks for temporal dynamics modeling, and self-attention mechanisms for adaptive feature refinement. The proposed architecture implements a three-stage computational pipeline. Initially, the CNN performs hierarchical extraction of localized patterns from multi-sensor tribological signals. Subsequently, the self-attention mechanism conducts adaptive recalibration of feature saliency, prioritizing diagnostically critical feature channels. Ultimately, bidirectional LSTM establishes cross-cyclic temporal dependencies, enabling cascaded fully connected layers with Gaussian activation to generate probabilistic wear state estimations. Experimental results demonstrate that the proposed model not only achieves superior predictive accuracy but also exhibits robust stability, offering a reliable solution for condition monitoring and predictive maintenance in industrial applications. Full article

(This article belongs to the Special Issue Future of Digital Tribology: Prediction of Tribological Performance Using Sensors, Signal Processing and Machine Learning)

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22 pages, 9751 KiB

Open AccessArticle

Investigation on the Coupling Effect of Bionic Micro-Texture Shape and Distribution on the Tribological Performance of Water-Lubricated Sliding Bearings

by Xiansheng Tang, Yunfei Lan, Sergei Bosiakov, Michael Zhuravkov, Tao He, Yang Xia and Yongtao Lyu

Lubricants 2025, 13(7), 305; https://doi.org/10.3390/lubricants13070305 - 14 Jul 2025

Abstract

Water-lubricated bearings (WLB), due to their pollution-free nature and low noise, are increasingly becoming critical components in aerospace, marine applications, high-speed railway transportation, precision machine tools, etc. However, in practice, water-lubricated bearings suffer severe friction and wear due to low-viscosity water, harsh conditions, [...] Read more.

Water-lubricated bearings (WLB), due to their pollution-free nature and low noise, are increasingly becoming critical components in aerospace, marine applications, high-speed railway transportation, precision machine tools, etc. However, in practice, water-lubricated bearings suffer severe friction and wear due to low-viscosity water, harsh conditions, and contaminants like sediment, which can compromise the lubricating film and shorten their lifespan. The implementation of micro-textures has been demonstrated to improve the tribological performance of water-lubricated bearings to a certain extent, leading to their widespread adoption for enhancing the frictional dynamics of sliding bearings. The shape, dimensions (including length, width, and depth), and distribution of these micro-textures have a significant influence on the frictional performance. Therefore, this study aims to explore the coupling effect of different micro-texture shapes and distributions on the frictional performance of water-lubricated sliding, using the computational fluid dynamics (CFD) analysis. The results indicate that strategically arranging textures across multiple regions can enhance the performance of the bearing. Specifically, placing linear groove textures in the outlet of the divergent zone and triangular textures in the divergent zone body maximize improvements in the load-carrying capacity and frictional performance. This specific configuration increases the load-carrying capacity by 7.3% and reduces the friction coefficient by 8.6%. Overall, this study provided critical theoretical and technical insights for the optimization of WLB, contributing to the advancement of clean energy technologies and the extension of critical bearing service life. Full article

(This article belongs to the Special Issue Water Lubricated Bearings)

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