Search Results (159)

This paper presents the results of experimental studies on the mechanical and tribological properties of samples produced using the fused filament fabrication method. These studies aim to identify a potential material for a water-lubricated sliding bearing that will be manufactured using 3D printing. Printed specimens fabricated from four different materials were analyzed for surface profile, mechanical properties via the instrumented indentation method, and tribological behavior using a pin-on-disc setup. Although increased hardness is generally associated with improved resistance to wear, the material that exhibited the lowest wear in the pin-on-disc tests was characterized by the lowest hardness among all investigated materials. The findings suggest that other aspects, including wear mechanisms, wear products, and tribolayer development, may also exert a substantial influence. Full article

This study investigates the tribological performance of chromium nitride (CrN)-coated polyether ether ketone (PEEK) polymers. CrN coating was deposited by physical vapor deposition (PVD) onto two commercially available substrates: neat PEEK and a modified PEEK. The suitability of the coated substrates for tribological applications was evaluated using ball-on-disc tests against stainless-steel (SS) counterparts. Differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA) confirmed the high thermal stability of the PEEK substrates, ensuring compatibility with low-temperature coating deposition. Microstructural analysis revealed dense and continuous CrN coatings with an average thickness of ~1.5 µm on both substrates. Tribological results of selected PEEK-based polymers showed that under the applied load of 2 N, uncoated PEEK substrates exhibited lower coefficients of friction (COFs) and smoother wear tracks compared with coated samples. In contrast, under the applied load of 4 N, CrN-coated PEEK substrates demonstrated reduced friction and improved stability relative to uncoated PEEK. This behavior is attributed to load-induced tribo-oxidation and the formation of a chromium-oxide-rich tribolayer that stabilized the sliding interface and suppressed adhesive wear. Overall, the results demonstrate that CrN coatings significantly enhance the load-bearing capacity and tribological performance of selected PEEK substrates under applied load of 4 N, highlighting their potential for advanced lightweight engineering applications requiring improved wear resistance. 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

In this study, AA7068 aluminum matrix composites reinforced with TiB₂/TiC were fabricated via mechanical alloying and microwave sintering to investigate the influence of reinforcement content and sintering temperature on microstructure, mechanical properties, and dry sliding wear. Mechanical alloying refined powders, reducing D₅₀ from 51.5 µm (AA) to 22.5 µm (AC9) and enhancing dispersion and retention of TiB₂/TiC particles. XRD confirmed α-Al as the dominant matrix phase, preserved TiB₂ and TiC phases, and limited MgAl₂O₄/ZnAl₂O₄ spinel formation. Crystallite refinement and increased lattice microstrain were observed with the addition of reinforcement. Microhardness increased with reinforcement content and sintering temperature, reaching 122.2 HV_0.05 in AC9-2. At the same time, the highest compressive strength was observed in AC6-2 (431.05 MPa), indicating that optimal load-bearing depends on densification and interfacial integrity rather than hardness alone. AC9-2 exhibited the best wear resistance, with a cumulative specific wear rate of 2.723 × 10⁻⁴ mm³/Nm over 1000 m. SEM-EDS analysis revealed oxide-rich tribolayers, mechanically mixed layers, TiB₂/TiC fragments, and Fe-rich third-body debris, indicating wear is predominantly hardness-controlled but strongly influenced by microstructural factors. Overall, TiB₂/TiC hybrid reinforcement improves AA7068 wear resistance through combined hard-particle load-bearing, reduced penetration, tribolayer stability, and third-body effects, offering insight for high-performance hybrid aluminum composites. 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

Graphene-reinforced CrCoNiFeMo high-entropy alloy composite coatings were fabricated on 17-4PH stainless steel by laser cladding for the surface protection of industrial robotic end-effector grippers. The effects of graphene content on microstructure, hardness, wear behavior and corrosion resistance were investigated. Graphene-derived carbon suppressed Laves and σ phases and promoted the in situ formation of M23C6, M7C3 and Co2C carbides, transforming the coating into a carbide-reinforced FCC/BCC composite structure. The average hardness increased from 462 HV0.2 to 676 HV0.2 with increasing graphene content. The 0.4 wt.% graphene coating showed the best wear resistance, with the lowest friction coefficient of 0.42 and minimum wear scar width and depth of 546 μm and 5.72 μm, which was attributed to carbide strengthening and the possible formation of a carbonaceous lubricating tribo-layer. The 0.2 wt.% graphene coating exhibited the best corrosion resistance, with the lowest corrosion current density of 5.81 μA/cm² and the highest impedance response. Excessive graphene caused carbon-rich agglomeration, excessive carbide precipitation and weakened passivation. This work provides a feasible surface strengthening strategy for 17-4PH stainless steel robotic gripper components. Full article

The temperature-dependent wear behavior of a cobalt-based Stellite 6 alloy was investigated from room temperature (RT) to 800 °C using high-temperature reciprocating sliding tests. The friction coefficient decreases monotonically with increasing temperature, from about 0.56 ± 0.12 at RT to 0.26 ± 0.11 at 800 °C, whereas the wear rate exhibits a pronounced non-monotonic evolution. Specifically, the wear rate increases from 18.4 ± 1.5 × 10⁻⁶ mm³·N⁻¹·m⁻¹ at RT to a maximum of 54.8 ± 1.6 × 10⁻⁶ mm³·N⁻¹·m⁻¹ at 600 °C, followed by an anomalous reduction to 10.2 ± 1.5 × 10⁻⁶ mm³·N⁻¹·m⁻¹ at 800 °C, which is even lower than that at RT. Microstructural and elemental analyses indicate that this behavior is governed by the temperature-dependent evolution of oxide layers. At RT–600 °C, thin and mechanically unstable oxide films repeatedly form and fracture, promoting oxidation-assisted abrasive and adhesive wear. In contrast, at 800 °C, a continuous and dense oxide layer forms and acts as a stable tribo-oxide film, effectively suppressing severe material removal. These findings clarify the temperature-driven wear mechanism transition of Stellite 6 alloy under high-temperature sliding conditions. Full article

Ti-6Al-4V ELI (Grade 23) fabricated by Laser Powder Bed Fusion (LPBF) exhibits well-known susceptibility to adhesive wear and tribo-oxidation under dry sliding, yet the tribological consequences of in-process laser remelting remain poorly characterized. This study investigates the influence of an in-layer laser scan strategy (single-scan and double-scan), normal forces in the 5–15 N range, and a sliding speed of 0.10–0.20 m·s⁻¹ on the dry sliding tribological response of additive manufactured Ti-6Al-4V ELI. A full factorial experimental design was carried out and the most significant factors and their contributions to the coefficient of friction, specific wear rate, and contact temperature were identified by a statistical method using a general linear model (GLM). The optimal parameters for both of the scan strategies were predicted using a response surface methodology (RSM). Furthermore, to assess the effect of the laser scan strategy and the in-layer remelting on the local mechanical properties, a microscale and nanoscale indentation was carried out. The results show that the normal load was the dominant factor with a contribution of 89.3% for the coefficient of friction, 54% for the specific wear rate, and 40.5% for the temperature. A significant load–scan strategy interaction that governed the wear behavior was detected. The double-scan strategy exhibited higher wear at 5 N but lower wear at 15 N than the single-scan, a counter-intuitive reversal attributed to the load-threshold tribolayer stabilization promoted by the remelting-induced near-surface microstructural modification. The novelty of this study was the setup of a robust GLM–RSM framework for predictive modeling and optimization of additively manufactured surfaces under tribological loading. Full article

Additive manufacturing through a laser cladding has been shown to be an effective technology for the mitigation of wear and rolling contact fatigue (RCF) of railway track. Small-scale tests have consistently shown that creating a thin layer of premium material on the tribo-active surface of the railhead vastly reduces wear and suppresses the onset of RCF due to the ratcheting mechanism being almost eliminated in comparison to standard rail material. Cladding reduces material plastic flow by 60% which is a cause of insulated track joint failure. This paper reports results from the first full-scale trials of additively manufactured laser clad layers on railway rails by studying their mechanical properties and microstructure. This is a vital step in safely progressing this technology from lab scale to network application. Tested full-scale insulated block joint (IBJ) specimens, clad with martensitic stainless steel (MSS) and Stellite 6, were sectioned, polished and etched and the microstructures of the clad, heat-affected zone and parent rail materials were inspected using optical and scanning electron microscopy (SEM) (Hitachi TM3030 plus, Tokyo, Japan). Residual stress was also measured. Cladding with MSS and Stellite 6 showed high wear and RCF resistance after the tests. Material flow was reduced with the clad layer applied. No defects such as porosity or large precipitates were observed in the heat-affected zone (HAZ), particularly close to the rail surface at the clad end which could act as a point of weakness. Residual stress states varied between materials, MSS being compressive (−344 MPa average) and Stellite 6 being tensile (+391 MPa average) which could have an impact on the fatigue life of the clad. This finding matches previous work, indicating that MSS may be preferable in the field, where bending of rails can occur. Overall, the work showed that laser cladding can provide a good solution to lipping issues and wear problems of rail in IBJs. Analysis in this work confirmed that the HAZ where clad meets the bulk rail at the surface has good structural integrity; however, this needs to be a focus of attention in field application of these layers. Full article

Background: The wear resistance of modern commercial glass-ceramic materials used in dental prostheses was investigated under cyclic contact conditions that included a rotational component. This loading mode has been largely overlooked in conventional in vitro wear testing, yet may be clinically relevant in patients with parafunctional conditions such as bruxism. Methods: Rotational loading was applied using an all-electric testing machine equipped with a biaxial actuator. Loading cycles combined a normal load (50 N) and a rotation (30°), at a frequency of 1 Hz. Microstructure and damage were characterized using advanced microscopy. Results: Rotational loading induced substantial damage across this class of materials, including the formation of glassy tribolayers with limited protective capability under the low-humidity conditions examined. Significant microstructure-dependent variations in wear volume were observed, with specific wear rates indicating severe wear (SWR above 10⁻⁶ mm³/N·m threshold) in three of the five materials tested. Lithium disilicate glass-ceramics, characterized by a high fraction of elongated reinforcement crystals, exhibited the greatest resistance to damage, whereas leucite-based glass-ceramics showed the lowest. The dominant wear mechanisms were plastic-deformation-induced grooving and fracture-driven chipping. The findings are interpreted within established wear models for brittle materials (Archard and fracture-based) and supported by numerical simulations of stress fields across multiple length scales. Implications: The results provide mechanistic insight into rotational wear damage in glass-ceramic systems, a material class particularly susceptible to such loading, and inform strategies for material selection and microstructural design aimed at improving prosthetic durability. Full article

With increasingly stringent requirements for wear resistance and reliability of functional coatings for heavily loaded friction units, a relevant challenge in materials science is to establish the relationships between the parameters of reactive pulsed magnetron sputtering and the tribo-mechanical properties of TiN/CrN multilayer systems. In this study, TiN/CrN multilayer coatings were deposited by reactive pulsed magnetron sputtering using separate titanium and chromium targets. The effect of the nitrogen flow rate (0.20–0.36 L/h) during chromium sputtering on the structure, phase composition, and mechanical and tribological properties of the coatings was investigated at a fixed nitrogen flow rate of 0.08 L/h for titanium. SEM, EDS, and XRD showed that increasing the nitrogen flow rate leads to a non-monotonic change in coating thickness (2.0–2.6 µm), caused by the transition of the chromium target from the metallic to the poisoned sputtering mode. At low N₂ flow rates, a subnitride Cr₂N phase forms in the structure, whereas at the optimal flow rate of 0.32 L/h the coating consists of stable TiN, CrN, and (Cr_0.5Ti_0.5)N phases. The coating nanohardness was 20–23 GPa and the Young’s modulus was 250–300 GPa. The best tribological performance was achieved at a nitrogen flow rate of 0.32 L/h, coefficient of friction μ ≈ 0.5 and a minimum wear rate of 1 × 10⁻⁵ mm³/(m·N), which correlates with the highest H³/E² value. It is shown that independent control of the CrN layer stoichiometry using separate targets can affect the tribo-mechanical properties of the TiN/CrN multilayer system. Full article

Laser Powder Bed Fusion (LPBF) enables the fabrication of complex titanium alloy components with high geometric freedom; however, surface integrity and tribological performance remain critical limitations for sliding-contact applications in biomedical and aerospace systems. In this study, the influence of in-layer laser remelting on the microstructure, surface topography, and dry sliding tribological behavior of LPBF-fabricated Ti-6Al-4V ELI (Grade 23) is systematically investigated. Disc-shaped specimens were produced using single-scan (SS) and double-scan (DS, in-layer remelting) strategies and tested in ball-on-disc configuration against AISI 52100 steel at a constant normal load of 10 N and three sliding speeds of 0.10, 0.15, and 0.20 m·s⁻¹. Microstructural and phase-related characteristics were analyzed by X-ray diffraction combined with Rietveld refinement and Warren–Averbach analysis, revealing that the DS strategy increases retained β-phase fraction (up to 5.2%) and promotes crystallite coarsening relative to the SS condition, without significantly altering bulk hardness. Surface morphology examined by SEM/EDS and AFM revealed a more homogeneous near-surface topography in the DS condition. Tribological results indicate that sliding speed governs steady-state friction and wear, with specific wear rates increasing progressively from 5.13 to 5.44 × 10⁻⁴ mm³·N⁻¹·m⁻¹ for SS and from 6.47 to 7.52 × 10⁻⁴ mm³·N⁻¹·m⁻¹ for DS across the investigated speed range. The DS specimens exhibited higher wear rates than the SS condition across all tested speeds, while steady-state COF values remained comparable between strategies, indicating that remelting-induced microstructural modifications affect material removal mechanisms without proportionally destabilizing the frictional regime. These findings suggest that in-layer laser remelting represents a process-integrated parameter with measurable consequences for surface integrity and tribological performance, though the generalizability of these results warrants validation across broader experimental conditions. Full article

Incorporating TiAl alloys in engine applications offers benefits including reduced fuel consumption and improved efficiency. However, understanding the wear behaviour of these materials is an important consideration due to their use in harsh environments involving movable parts. This study investigated the wear behaviour and mechanisms of Ti–48Al–2Nb–0.3Si-1Sn (TiAl–S1) together with Ti–48Al–2Nb–0.3Si (TiAl–S0) as a reference alloy against an alumina ball. Scanning electron microscopy (SEM) analysis showed that the addition of Sn refined the lamellar structure from 216 $\mu \mathrm{m}$ to 130 $\mu \mathrm{m}$ and promoted more uniform deformation. SEM observations also indicated that abrasive wear is the dominant mechanism in the TiAl alloys. The TiAl–S1 exhibited lower hardness, resulting in deformation of wear debris and promoting third body acting as a lubricant. SEM-EDS revealed that the tribo-layer and wear debris originated from the TiAl materials rather than the counterpart alumina material. Both alloys demonstrated noble wear resistance, with a wear rate of 7.542 × 10⁻⁶ mm³/Nm for TiAl–S1 and 6.729 × 10⁻⁶ mm³/Nm for TiAl–S0. Even though both TiAl alloys experienced abrasive wear mechanisms, the addition of Sn emerges as a promising alloying strategy, for enhancing ductility without significantly increasing material loss. Full article

The harvesting of energy from movements is one of the purposes of triboelectric nanogenerators (TENGs). Among the various devices designed to perform this function, floors are one of the primary ones, as they do not need to be individually fitted to each subject and can be manufactured and installed on a large scale. This work classifies previously published TENG-based floors based on their materials, electrical performance in terms of the voltage, current, and power they produce, and their application in different fields. The materials used have been correlated with other important aspects for floors, such as weather or flame resistance, sustainability, recyclability or biodegradability of materials, and price. The synthesis of the variety of TENG-based floor models, which incorporate novel materials, hybrid technologies, or various functionalities, among other characteristics, can enrich and inspire the reader to enhance the performance of future floor designs based on the triboelectric effect. In addition, a novel triboelectric floor design made of nitrile butadiene rubber (NBR) and fluorine kautschuk material is presented, along with the electrical power generated when tribolayers are in contact. For the three floor strips measuring 40 cm long × 4 cm wide and 1 mm thick, electrical current and voltage output was measured, achieving nearly 0.1 W (20 V & 4.5 mA) of electrical power generation. Full article

This study investigates the multi-scale tribo–thermo–viscoelastic performance of a sustainable bio-based FormuLITE epoxy reinforced with single and hybrid carbon nanofillers (0.1 wt.% total loading) under dry sliding up to 50 N. Pin-on-disk tests at 10, 30, and 50 N showed a consistent reduction in contact pressure and wear volume in the order: neat epoxy > 0.1 CNT > 0.1 GNP > 0.1 ND > 0.1 CNT/GNP > 0.1 CNT/ND > 0.1 GNP/ND. At 50 N and 1500 m sliding distance, neat epoxy exhibited a wear volume of 13.43 mm³ and contact pressure of 13.4 N/cm², while the GNP/ND hybrid reduced wear to 4.86 mm³ and contact pressure to 6.2 N/cm², corresponding to reductions of 64% and 54%, respectively. The accelerating wear coefficient decreased from 2.9 × 10⁻⁶ to 8.5 × 10⁻⁷, confirming slower damage accumulation in hybrid systems. Time-dependent contact pressure analysis revealed reduced asymptotic intensity and suppressed mid-cycle pressure spikes, indicating enhanced tribolayer stability. Effective surface hardness increased from 0.18 GPa (neat epoxy) to 0.30 GPa (GNP/ND), while normalized wear decreased from 1.00 to 0.36. Enhanced damping behavior and improved thermal conductivity in hybrid systems promoted stress redistribution and minimized flash-temperature localization. An interfacial energy-partition framework calibrated to experimental wear data quantitatively linked effective driving pressure, tribofilm stabilization, and surface hardness to material removal. The results demonstrate that wear mitigation in sustainable bio-epoxy systems is governed by coupled mechanical, viscoelastic, and thermal energy redistribution, with GNP/ND hybrids providing the most stable tribological interface under severe sliding. The findings contribute to the development of durable and sustainable bio-epoxy composite systems for engineering applications, supporting broader goals of responsible material utilization and sustainable industrial innovation aligned with the United Nations Sustainable Development Goals (SDG 9 and SDG 12). Full article