Search Results (430)

This study investigates the tribological performance of three commercial PTFE-based Xylan^® coatings—Xylan^® 1425, Xylan^® 1052, and Xylan^® 1010—applied to 18CrNiMo7-6 steel under dry sliding conditions. Ball-on-Disk tests were conducted at normal loads of 5, 7.5, and 10 N, wear-track radii of 12, 16, and 20 mm, and corresponding sliding velocities of 0.31–0.52 m·s⁻¹. The tribological evaluation was complemented by measurements of coating thickness, surface roughness, nanoindentation, wear-track profilometry, scanning electron microscopy, EDS mapping, and post-test cross-sectional microscopy. All coatings reduced the coefficient of friction from approximately 0.49–0.64 for the uncoated steel to 0.09–0.13, corresponding to an average reduction of 78–80%. Xylan^® 1425 exhibited the highest nanohardness of 57.02 MPa, the highest reduced elastic modulus of 3.33 GPa, and the most favorable elastoplastic indices. It also achieved the lowest wear, with a volumetric loss of approximately 0.03 mm³ under the most severe conditions, representing a reduction of more than 99% compared with the substrate. Xylan^® 1010 provided the lowest friction but showed pronounced plastic deformation, whereas Xylan^® 1052 exhibited fragmentation and increased wear. Post-test cross-sectional microscopy confirmed local exposure of the steel substrate in both coatings. Overall, Xylan^® 1425 provided the best balance of low friction, mechanical stability, coating continuity, and wear resistance. Full article

Ultra-high molecular weight polyethylene (UHMWPE) is the preferred bearing material for total knee arthroplasty, yet its limited service life (15–20 years) remains a clinical challenge. This study investigates graphene oxide (GO) nanoplatelets as reinforcing fillers to enhance the mechanical and tribological performance of UHMWPE for longer-lasting implants. GO/UHMWPE composites with 0–1 wt% GO were fabricated via solution blending and hot compression molding. Direct SEM imaging combined with oxygen elemental mapping confirmed uniform GO dispersion up to 0.5 wt%, whereas higher loadings induced agglomeration. Dynamic mechanical analysis showed that the storage modulus at 37 °C increased with GO content, peaking at 0.5 wt% (improved by ~28% over neat UHMWPE), then decreased due to aggregation. Tribological tests under dry reciprocating sliding revealed that GO progressively reduced the wear rate (up to ~45% at 1.0 wt%), but also raised the steady-state friction coefficient from 0.13 to 0.19, attributed to molecular chain anchoring. The optimal balance of enhanced stiffness and wear resistance, with only a marginal friction increase, was achieved at 0.5 wt% GO. The reinforcement mechanism involves efficient stress transfer to rigid GO sheets and reduced surface peeling. This work provides a robust processing route and direct dispersion evidence, offering practical guidance for designing high-performance UHMWPE composites for orthopedic applications. Full article

Aluminum matrix composites (AMCs) reinforced with natural mineral ilmenite offer a cost-effective and thermally stable alternative to conventional cast iron brake drum materials. This study investigates the synergistic effect of fine (32–50 µm) and coarse (75–106 µm) ilmenite particles at four fine-to-coarse weight ratios (1:4, 2:3, 3:2, and 4:1) and three reinforcement contents (5, 10, and 15 wt.%) on the thermal stability and dry sliding wear behavior of stir-cast LM30 Al composites. Ilmenite reinforcement progressively reduces the coefficient of thermal expansion of the LM30 matrix, with the 15 wt.% 4:1 fine-to-coarse ratio composite (15DRP41) exhibiting the lowest coefficient of thermal expansion of ~16.54 × 10⁻⁶/°C, a ~33.3% reduction relative to the unreinforced alloy (~24.8 × 10⁻⁶/°C). The 15DRP41 composite demonstrates the lowest wear rate of all the fabricated composites, 1.82 × 10⁻³ mm³/m at 9.81 N and 9.56 × 10⁻³ mm³/m at 68.67 N at 200 °C. Under the most severe load condition (68.67 N, 200 °C), the coefficient of friction of 15DRP41 is reduced by up to 44% compared with the LM30 alloy. A comparative test against commercial grey cast iron shows that 15DRP41 has a similar wear rate up to 200 °C, while its density (~2.9 g/cm³) is significantly lower and it has excellent dimensional stability. Scanning electron microscopy and energy-dispersive X-ray spectroscopy of worn surfaces and debris confirm a progressive change from oxidative and mild abrasive wear at low loads and temperatures to severe wear by delamination at 68.67 N and 300 °C, as evidenced by the presence of a multi-component mechanically mixed layer. The results have confirmed that the optimum fine-to-coarse ratio for the reinforcement was 4:1, which led to the maximum wear resistance and thermal stability in ilmenite-reinforced LM30 composites for lightweight automotive brake drum applications, and that the optimum weight percentage for the reinforcement was 15 wt.%. Full article

To elucidate the effect of cyclic hot forging and short-time aging (HFSTA) on the wear resistance of a Cu-Cr-Zr alloy, samples in the as-received state (solution-treated at 1000 °C) and after 4 passes and 6 passes of cyclic HFSTA at 450 °C were prepared. The relationships between microstructure and properties were systematically analyzed. The results indicate that the cyclic HFSTA process did not change the main phase structure of the Cu matrix but significantly tailored the grain morphology, local misorientation, grain boundary character, and tribo-chemical behavior of the surface. The 4-passes sample possessed relatively high hardness, electrical conductivity, and favorable microstructural stability and was able to form a continuous and dense oxide protective film during friction, as demonstrated by the increase in hardness from 86 HV (as-received) to 195 HV, the decrease in average coefficient of friction (COF) from 0.65 to 0.50, and the reduction in wear rate from 13.3 × 10⁻⁴ mm³/(N·m) to 0.3 × 10⁻⁴ mm³/(N·m). The 6-passes sample exhibited slightly higher hardness, but the increased proportion of low-angle grain boundaries (LAGBs) intensified cracking and spallation on the wear track, causing the wear rate to rebound to approximately 8.2 × 10⁻⁴ mm³/(N·m). The study demonstrates that the wear resistance of the Cu-Cr-Zr alloy does not improve monotonically with hardness or grain refinement but is jointly controlled by precipitation strengthening, dislocation/substructure strengthening, surface damage tolerance, and the stability of the tribo-film. For the dry sliding service conditions of Cu-Cr-Zr alloys, 4 passes of cyclic HFSTA at 450 °C represent an optimal processing window that balances mechanical properties, electrical conductivity, and wear resistance, providing guidance for the process optimization of components such as contact wires and welding electrodes. Full article

Polyurethane (PU) foams are widely used in footwear midsoles because their cellular structure, density, impact-attenuation capability, and mechanical durability can be tailored through formulation design. In this study, polyester-based PU foams were prepared at different isocyanate indices while keeping the main formulation components constant, and their structure-property relationships were evaluated under midsole-relevant conditions. The samples were characterized by density, tensile and compression testing, standard abrasion wear testing, water absorption, temperature-dependent flexural resistance, Fourier transform infrared (FTIR), scanning electron microscope (SEM), differential scanning calorimetry (DSC), thermogravimetric analysis/derivative thermogravimetry (TGA/DTG), and dry/wet tribometry. FTIR results confirmed the formation of urethane/urea-related linkages and the absence of detectable residual isocyanate groups, whereas DSC indicated broad heat-flow events typical of segmented PU systems, including high-temperature events that should be interpreted together with TGA. TGA/DTG analysis showed similar initial degradation behavior for all formulations; however, the 138-index sample exhibited the highest t_90% value, indicating improved high-temperature mass retention. Tribometric tests revealed an environment-dependent coefficient of friction (COF) response: the 138-index sample exhibited the lowest steady-state COF under dry sliding (μ_ss = 0.211), whereas the 113-index sample showed the lowest COF value under wet sliding conditions (μ_ss = 0.176). Overall, among the three stable formulations investigated, the 113-index formulation exhibited the most balanced multi-property performance. These results suggest that, within the tested formulation range, midsole-relevant PU foam performance is associated with a balance of formulation characteristics rather than simply with increasing the isocyanate index. Full article

High-velocity oxy-fuel (HVOF)-sprayed NiCrBSi coatings containing 0, 10, 30, and 50 wt.% WC-Co were evaluated on AZ91D magnesium alloy to determine how the discrete reinforcement level affects surface topography, phase constitution, Vickers microhardness, dry-sliding friction, mass loss, and wear-track microchemistry. As-sprayed surfaces were characterized by three-dimensional profilometry; coating cross-sections and worn surfaces by optical microscopy and SEM/EDS; phase constitution by XRD; and mechanical response by HV_0.1 indentation. Dry-sliding tests were performed at 10, 30, and 50 N over 100–1000 m. Increasing WC-Co content raised Sa from 8.8 ± 0.3 to 13.0 ± 0.5 µm and Vickers microhardness from 776 ± 4 to 959 ± 5 HV_0.1. XRD indicated a γ-Ni-based matrix containing boride/carbide constituents, while WC, W₂C, and Co became increasingly prominent in the reinforced coatings. Boride assignments are based on diffraction evidence, whereas B and C EDS signals were treated semi-quantitatively. The 50 wt.% WC-Co coating exhibited the lowest mass loss and mean coefficient of friction at every load. Its mean friction coefficients were 0.31, 0.35, and 0.41 at 10, 30, and 50 N, corresponding to reductions of 40.1%, 38.9%, and 36.2% relative to AZ91D. At 1000 m, its mass-normalized wear rate indices were 9.0 × 10⁻⁴, 4.0 × 10⁻⁴, and 5.3 × 10⁻⁴ mg N⁻¹ m⁻¹, respectively. Post-wear mapping showed the largest field-scale W-Co-rich fraction in the 50 wt.% coating; however, isolated spectra containing more than 94 wt.% Mg are compatible with local coating penetration/substrate exposure and/or Mg-rich debris. The 50 wt.% composition therefore provided the best combined response among the four tested levels, while intermediate compositions are required to identify a continuous-composition optimum. Full article

Additive manufacturing (AM) of stainless steel has been gaining industry attention in recent years due to the need to manufacture complex steel components. Many sectors stand to benefit from the design flexibility, customization, and rapid production capabilities of AM. However, the industry’s adoption of this technology remains limited due to concerns about the mechanical integrity and reliability of AM products. This experimental study examines the wear and tribological behavior of Wire Arc Additive Manufactured (WAAM) austenitic stainless steel 316L. Pin-on-disk tests were conducted using a 5 mm tungsten carbide ball under dry sliding conditions at normal loads of 1.5 and 2.5 N and sliding speeds between 0.03 and 0.229 m/s. The results showed that the coefficient of friction remained relatively stable at approximately 0.6, while wear volume generally decreased with increasing sliding speed. Lower normal loads resulted in lower wear volume, whereas the wear factor showed only limited sensitivity to the applied load. Optical microscopy revealed a ferrite–austenite microstructure with residual δ-ferrite that contributes to the observed wear behavior. These findings demonstrate the suitability of WAAM-produced 316L stainless steel for tribological applications requiring stable frictional performance. Full article

Poly(methyl methacrylate) (PMMA) remains a clinically important denture base polymer because of its favorable processability, aesthetics, repairability and long-term prosthodontic use; however, its limited surface hardness and susceptibility to sliding-induced degradation constrain surface durability. This study establishes the structure–chemistry–microstructure–tribology relationships and composition-window predictive behavior of heat-polymerized PMMA reinforced with titanium diboride (TiB₂). PMMA/TiB₂ composites containing 1, 3 and 5 wt.% TiB₂ were prepared and compared with unreinforced PMMA. X-ray diffraction confirmed preservation of the broad amorphous/semi-amorphous PMMA response, while TiB₂-related crystalline features became increasingly detectable with reinforcement content. ATR-FTIR showed retention of the characteristic C–H, ester C=O and C–O/C–O–C vibrations. SEM/EDS demonstrated progressively greater particle-related surface contrast and local Ti/B-associated elemental signatures. Vickers microhardness increased from 20.0 ± 0.7 to 35.0 ± 1.39 HV0.03, corresponding to a 75.0% improvement at 5 wt.% TiB₂. After 1000 m of dry sliding, total mass loss decreased from 32.4 ± 0.5 to 14.9 ± 0.4 mg (54.0% reduction), overall coefficient of friction decreased from 0.58 to 0.35, and representative wear-track width decreased from 481.4 to 101.8 µm. A parsimonious distance–composition interaction model retained strong grouped leave-one-composition-out performance for cumulative wear (R² = 0.9622; RMSE = 1.53 mg), while a linear composition model provided the most robust hardness prediction (R² = 0.9317; RMSE = 1.50 HV0.03). More complex nonlinear models did not improve prediction for held-out compositions. Within the investigated 0–5 wt.% window, 5 wt.% TiB₂ provided the most effective combination of matrix preservation, surface hardening, wear suppression and frictional stabilization. Full article

Self-lubricating iron-based composites produced by powder metallurgy are promising materials for reducing friction and improving component durability under dry-sliding conditions. In this study, three composites reinforced with graphite and/or graphene oxide (Fe10%Gr, Fe10%GO, and Fe5%Gr5%GO) were fabricated to evaluate the influence of solid lubricants on densification, hardness, and tribological behavior. Powders were uniaxially compacted at 500 MPa and low-temperature-sintered at 880 °C under an argon atmosphere. The tribological performance was assessed by pin-on-disk tests against an AISI 52100 steel ball. Pure Fe exhibited the highest hardness (approximately 97 HV) and a final porosity of 17.5%, whereas the lubricant-containing composites showed porosities ranging from 17.3% to 22.8% and lower hardness values of 45–60 HV. Despite the reduction in hardness, all lubricant-containing compositions decreased the coefficient of friction relative to pure Fe (~0.33). Fe10%Gr and Fe5%Gr5%GO exhibited the lowest friction coefficients, reaching ~0.08 and ~0.05, respectively, while Fe10%GO showed the highest wear rate (~1.1 × 10⁻² mm³/Nm). Among the compositions studied, Fe5%Gr5%GO showed the best friction–wear balance among the self-lubricating formulations, combining low friction and moderate wear due to a surface synergy where graphite promotes continuous low-shear lubrication while GO promotes the formation of a more compact and resilient protective tribolayer. Full article

Cobalt–chromium (CoCr) alloys have gained significant importance in the field of medical implants due to their outstanding combination of mechanical strength and excellent wear and corrosion resistance. Compared with other state-of-the-art materials, such as stainless steel or titanium, CoCr alloys typically exhibit superior fatigue strength, which is particularly advantageous for implants and components exposed to long-term repetitive loading. The present study investigates the feasibility of using commercially available CoCr alloy powders in the Laser Powder Bed Fusion (PBF-LB/M) process for the fabrication of biomedical implants. Microstructural characterization of the PBF-LB/M-manufactured CoCr samples revealed a dense, refined cellular–dendritic microstructure with a high degree of densification, characteristic of the rapid solidification associated with the PBF-LB/M process. The evaluation of mechanical performance, wear behavior, and corrosion resistance provides valuable insights into the suitability of these alloys for biomedical applications, especially in the design of complex implants requiring enhanced durability and long-term reliability. Furthermore, compression testing highlighted the influence of layer orientation on mechanical properties, emphasizing the importance of strategic prototyping and building orientation selection in the PBF-LB/M process. Tribological behavior assessed under dry sliding conditions demonstrated a significantly reduced coefficient of friction and lower wear rate compared to a conventional 316L stainless steel, which is frequently used in similar applications. Corrosion resistance was evaluated by potentiodynamic polarization measurements in Ringer electrolyte, showing that the PBF-LB/M-fabricated CoCr samples exhibit good corrosion resistance in environments resembling physiological fluids. Overall, the PBF-LB/M technique represents a promising manufacturing route for next-generation CoCr biomedical implants, particularly for orthopedic and dental applications. Beyond the biomedical field, the findings of this study also support the potential extension of PBF-LB/M-processed CoCr alloys to industrial sectors requiring high wear and corrosion resistance, including aerospace and automotive applications. Full article

This study investigates the influence of barrel filling ratio on the microstructure, phase composition, and tribological performance of detonation-sprayed Cr₃C₂–NiCr coatings. Coatings were deposited at barrel filling ratios of 43% and 53% under identical spraying conditions. Microstructural characterization revealed the formation of dense lamellar coatings with low porosity and uniform distribution of Cr₃C₂ carbide particles within the NiCr metallic matrix. Compared with the coating deposited at a barrel filling ratio of 43%, the coating deposited at 53% exhibited a denser microstructure. X-ray diffraction analysis confirmed that Cr₃C₂ and NiCr remained the dominant phases after spraying, while a minor amount of Cr₇C₃ formed due to partial decarburization of chromium carbide during thermal exposure. Tribological performance was evaluated under dry sliding conditions using a ball-on-disc configuration at normal loads of 10 and 15 N and sliding speeds of 5 and 10 cm/s. Wear volume was determined from the geometry of the wear track after testing, and wear rate was calculated accordingly. The coating produced at a barrel filling ratio of 53% demonstrated improved wear resistance under elevated loads despite exhibiting a higher coefficient of friction. The minimum wear rate reached 1.23 × 10⁻⁴ mm³/(m·N), which was associated with reduced porosity and enhanced structural integrity of the coating. The obtained results demonstrate that optimization of detonation spraying parameters significantly affects coating structure and tribological behavior. The developed Cr₃C₂–NiCr coatings are promising protective materials for components operating under severe friction and wear conditions, including industrial and high-temperature engineering applications. Full article

High-velocity oxy-fuel (HVOF) spraying was used to deposit WC-Co and WC-Co-Cr coatings on high-speed steel in order to determine how binder chemistry and coating thickness jointly control load support, friction, and dry sliding wear resistance. Nominal 50 and 100 µm coatings were compared within the same substrate framework by XRD, FT-IR, SEM/EDX, cross-sectional image analysis, Vickers hardness testing, dry sliding wear testing, and post-wear SEM/EDX. The coatings retained WC as the dominant crystalline phase, while weak overlapping features were associated with binder-rich regions and limited decarburization products. Cross-sectional observations confirmed continuous coating build-up close to the nominal thicknesses and low apparent dark-feature/porosity fractions. All WC-based coatings increased the effective hardness and reduced mass loss relative to uncoated HSS. Among the tested conditions, WC-Co-Cr-100 provided the highest effective hardness and the lowest mass loss after 1000 m sliding, whereas WC-Co-100 produced the lowest mean coefficient of friction. The results show that low friction and high wear resistance are not governed by identical mechanisms: WC-Co favours interfacial shear reduction, while the thicker Cr-containing coating provides superior resistance to material removal through improved carbide retention, binder stability, and coating-scale load support. Full article

Plasma electrolytic oxidation (PEO) has emerged as a leading surface engineering technology for improving the tribological and corrosion performance of lightweight structural alloys, including aluminum, magnesium, titanium, and zirconium. Unlike conventional anodizing or line-of-sight deposition processes, PEO forms thick, multiphase ceramic oxide coatings metallurgically bonded to the substrate through plasma-assisted in situ oxidation, enabling treatment of complex and internal geometries that competing technologies cannot reach. The tribological performance of PEO coatings is governed by coupled interactions among electrolyte chemistry, electrical discharge behavior, phase evolution, porosity development, and residual stress state. This review critically evaluates the friction, wear, and tribo-corrosion behavior of PEO coatings under dry sliding, lubricated, high-temperature, marine, and vacuum environments, and systematically examines the influence of processing parameters, microstructural evolution, transfer layer formation, and counterface interactions on coating performance. Hybrid and duplex systems incorporating solid lubricants, polymer impregnation, sol–gel sealing, and multilayer architectures are discussed as strategies to overcome limitations associated with brittleness and surface porosity. Current research challenges, including fatigue degradation, coating defect control, limited cross-study standardization, and incomplete mechanistic understanding of process–microstructure, tribological relationships, are critically assessed. Emerging directions encompassing self-lubricating adaptive coatings, AI-guided process optimization, and multifunctional hybrid architectures are highlighted as pathways toward next-generation surface systems. This review provides a mechanism-based framework for understanding tribological behavior in PEO coatings and identifies critical opportunities for future industrial implementation in aerospace, automotive, marine, biomedical, and energy applications. Full article

CoCrFeMnNi high-entropy alloy (HEA) coatings were fabricated on an S41500 stainless steel substrate by laser cladding and subsequently strengthened using machine hammer peening (MHP) at three hammering energies of 1.7 J, 3.5 J, and 5.0 J. The effects of MHP treatment on the phase structure, surface morphology, microhardness, and tribological properties of the coatings were systematically investigated. The results showed that all coatings retained a single-phase face-centered cubic (FCC) structure after MHP treatment, indicating excellent microstructural stability during impact-induced strengthening. With increasing hammering energy, the surface morphology gradually evolved from discrete hammering indentations to a more continuous orange-peel-like texture, while the surface roughness initially increased and then decreased. MHP significantly enhanced the surface hardness of the coatings. In particular, the MHP3.5 sample exhibited the highest surface hardness of approximately 420 HV, representing an increase of about 120% compared with the untreated coating. Under dry sliding conditions at a load of 30 N, the MHP3.5 sample exhibited the lowest and most stable friction coefficient, maintaining a steady-state value of approximately 0.40–0.45. Its specific wear rate decreased by nearly 45% compared with that of the untreated coating. The improved wear resistance was mainly attributed to the combined effects of strain hardening, grain refinement, and dislocation strengthening induced by machine hammer peening. Considering the hardness, friction coefficient, and specific wear rate results together, a hammering energy of 3.5 J was identified as the most suitable MHP parameter under the low-load wear conditions investigated in this study. Full article

Friction and wear are major factors affecting the efficiency and reliability of mechanical systems, leading to increasing interest in laser surface texturing (LST) for tribological surface engineering. This review summarizes the development of LST from conventional surface modification to multifunctional interface design and discusses the underlying process–structure–performance relationships. Different lubrication-dependent mechanisms, including micro-hydrodynamic pressure generation, wear debris entrapment, contact stress regulation, metallurgical strengthening, and wettability control, are analyzed under hydrodynamic, boundary, and dry sliding conditions. Representative processing technologies, including nanosecond, ultrafast, direct laser interference patterning (DLIP), and liquid-assisted laser processing, are compared in terms of fabrication precision, thermal effects, scalability, and tribological performance. Recent advances in hybrid surface engineering strategies integrating textures with coatings, solid lubricants, and surface hardening treatments are also reviewed. Representative applications involving bearings, cutting tools, biomedical implants, advanced ceramics, and additively manufactured materials are discussed to summarize application-oriented texture design principles. Current limitations related to thermal damage, manufacturing efficiency, coating stability, and long-term reliability are critically evaluated. Future developments are expected to focus on multifunctional surface integration, large-area manufacturing, and AI-assisted optimization for application-specific tribological interface design. Full article