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Friction and Wear Behaviors in Mechanical Engineering

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A special issue of Coatings (ISSN 2079-6412). This special issue belongs to the section "Tribology".

Deadline for manuscript submissions: 30 April 2025 | Viewed by 13623

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Prof. Dr. Juozas Padgurskas

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Department of Mechanical, Energy and Biotechnology Engineering, Faculty of Engineering, Vytautas Magnus University, LT-53361 Kaunas, Lithuania
Interests: green tribology; biotribology; nanoparticles in lubricants; biodegradable oils; monitoring of tribosystems
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Dr. Raimundas Rukuiža

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Department of Mechanical, Energy and Biotechnology Engineering, Faculty of Engineering, Vytautas Magnus University, LT-53361 Kaunas, Lithuania
Interests: friction and wear reducing coatings; green tribology materials; bio-degradable oils; nano-particles in lubricants; self-regulation in tribo systems
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We would like to invite you to submit your work for the Special Issue “Friction and Wear Behaviours in Mechanical Engineering”. The friction and wear problems in mechanical systems have always been particularly important, but recently, with the worsening of energy problems, the relevance of these issues has increased even more. When solving this question, special attention should be focused on the systematicity of the solution, i.e., analysis of the entire tribological system. We invite articles that deal with the properties of friction surfaces; their change using various technological methods, both when forming coatings and applying other surface modification methods; and tribological system lubrication. We also seek articles dedicated to the loss of and increase in tribological system efficiency, mechanisms of surface wear and degradation, and the monitoring of tribological systems. The most important highlights of this publication are new and combined surface coating and processing methods; self-lubricating coatings; tribological properties of lubricants; their improvement and assessment of changes in properties during the operation; green, i.e., environmentally friendly technologies; and biodegradable lubricants. We welcome contributions that evaluate not only the friction and wear parameters of the tribological system, but also friction mechanisms, surface degradation processes, and environmentally friendly materials (i.e., bioscale and structural and lubricating materials made from renewable materials).

Most of the articles in the Special Issue will consist of published reports of the international conference BALTTRIB'2022 (www.balttrib.info).

The topics of interest include, but are not limited to, the following:

New and combined methods of coating formation and surface modification;
Influence of surface treatment on its wear and degradation mechanisms and intensity;
Structural and lubricating materials of biological origin;
Self-lubrication coatings and self-regulation processes in friction pairs;
Green surface treatment technologies;
Green tribology.

Prof. Dr. Juozas Padgurskas
Dr. Raimundas Rukuiža
Guest Editors

Manuscript Submission Information

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

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

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

Keywords

surface modification
tribosystem
friction and wear mechanisms
biolubricants
biodegradable materials
green tribology

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Published Papers (10 papers)

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Research

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24 pages, 7590 KiB

Open AccessArticle

The Influence of Roughness of Surfaces on Wear Mechanisms in Metal–Rock Interactions

by Vlad Alexandru Florea, Mihaela Toderaș and Ciprian Danciu

Coatings 2025, 15(2), 150; https://doi.org/10.3390/coatings15020150 - 30 Jan 2025

Viewed by 516

Abstract

The processes of rock excavation and processing involve intense mechanical stresses on cutting, displacing, and transporting tools, inevitably leading to the phenomenon of dry friction wear. The factors influencing the intensity and mechanisms of wear are complex and interdependent, being conditioned by the physical–mechanical properties of the rocks, the geometric characteristics and materials of the tools, as well as the cutting process parameters (cutting force, feed rate). Previous studies have mainly addressed the global aspect of wear without delving into the microstructural evolution of the contact surfaces during the friction process. In this paper, through controlled tribometric tests, we have investigated in detail the abrasive wear mechanisms of metallic materials in contact with different types of rocks, with an emphasis on the role played by surface roughness and the mineralogical properties of the rocks. Experimentally, we varied the applied forces and the number of friction cycles to simulate different working conditions and evaluate how these parameters influence wear intensity and surface morphology evolution. Microstructural analysis of the samples, combined with roughness measurements, allowed the identification of the predominant degradation mechanisms (abrasion, adhesion, fatigue) and their correlation with the material properties and the friction process parameters. The results have shown a strong correlation between the wear capacity of rocks and their petrographic properties, such as hardness, porosity, and hard mineral content. It was also found that the roughness of the contact surfaces plays an essential role in wear mechanisms, influencing both the initiation and propagation of its effects. Depending on the experimental data, we have developed a classification of rocks based on their abrasive potential and proposed criteria for the optimal adoption of materials and working parameters for the tools of technological equipment depending on the type of rock encountered. The results of this study can contribute to improving the durability of tools, as well as mining equipment, and reducing operating costs. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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18 pages, 12949 KiB

Open AccessArticle

Influence of the Applied WC/C and CrN + WC/C Coatings on the Surface Protection of X2CrNi18-9 Cavitation Generators

by Wojciech Borek, Tomasz Linek, Tomasz Tański and Perumal Sureshkumar

Coatings 2025, 15(1), 87; https://doi.org/10.3390/coatings15010087 - 15 Jan 2025

Viewed by 477

Abstract

The purpose of this paper is to investigate the impact of the applied WC/C and CrN + WC/C protective coatings applied using various PVD methods as protection for cavitation generators operating in an environment of intense cavitation wear. In order to carry out planned tasks, special devices generating a cavitation environment have been designed and manufactured. As part of this study, an analysis of the surface of cavitation generators, both before applying the coatings and with the applied protective PVD coatings, and also before and after operation in a cavitation environment, was carried out using the following research techniques: stereoscopic microscopy, scanning electron microscopy, transmission microscopy, XRD, and confocal microscopy. Despite the use of corrosion-resistant steels as a result of the cavitation environment, this causes surface material wear, especially in the area of the through holes. This is due to the fact that there are no protective coatings inside the through hole. Moreover, it was found that, for the tested steel with multilayer CrN + WC/C coatings, there were significantly fewer cavitation defects both on the surface of the material and on the edge of through holes, which indicates that the use of these multilayer coatings can significantly extend the service life of structural elements operating in such environmental conditions. Based on the conducted research tests, it was proven that the applying protective coatings significantly reduce the wear of the surfaces of the tested cavitation generators, thus allowing the use of cheaper steels, not resistant to corrosion, e.g., P265GH steel, which is five times cheaper than austenitic steel. The P265GH steel is used for structural elements in the heating, petrochemical, energy, food, and chemical industries, as well as for structural elements in the aviation, shipbuilding, and many other industries, and, thus, it is possible to reduce the costs associated with the operation of this construction solution in industrial conditions. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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21 pages, 73296 KiB

Open AccessArticle

Experimental Research on the Tribological Behavior of Plastic Materials with Friction Properties, with Applications to Manipulators in the Pharmaceutical Industry

by Maria Stoica, Marius Gabriel Petrescu, Razvan George Ripeanu, Eugen Laudacescu and Maria Tănase

Coatings 2025, 15(1), 84; https://doi.org/10.3390/coatings15010084 - 14 Jan 2025

Viewed by 447

Abstract

In this article, the authors present the results obtained within a complex experimental program that focuses on determining the tribological characteristics of the friction materials used in transmission belts, which are critical active components in manipulators within the pharmaceutical industry. The elements of transmission belts, having the role of ensuring the movement of cardboard packaging—used when packing the foils with medicine capsules—and stopping them during the insertion of the foils, were studied. This repetitive cycle—travel-braking—leads to the wearing of the friction material on the active surface of the belt. The experiments were carried out in a dry environment (air) by testing different types of friction materials (original belt, 3D printed TPU 60A, and TPU 95A). While the study is limited to these three materials, the results highlight the significant influence of material type and infill percentage on the coefficient of friction (COF) and wear resistance. TPU 60A achieved the highest COF at 100% infill, indicating a superior grip but experienced substantial wear, under the same conditions. Conversely, TPU 95A demonstrated a lower COF, suggesting reduced grip, but exhibited exceptional wear resistance. The aim of the research is to provide a preliminary investigation into the materials’ wear resistance and braking effectiveness. The experiments utilized appropriate samples to replicate real operational conditions, particularly focusing on the nature of contact between the moving belt and the packaging. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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30 pages, 14918 KiB

Open AccessArticle

Wear Mechanism of an AlCrN-Coated Solid Carbide Endmill Cutter and Machined Surface Quality under Eco-Friendly Settings during Open Slot Milling of Tempered JIS SKD11 Steel

by Ly Chanh Trung and Tran Thien Phuc

Coatings 2024, 14(8), 923; https://doi.org/10.3390/coatings14080923 - 23 Jul 2024

Viewed by 922

Abstract

In the die and mold industry, tempered JIS SKD11 steel is selected to manufacture cold-forming dies that require an optimum balance of toughness, strength, and wear resistance. Therefore, the machinability of tempered JIS SKD11 in the milling machining process is challenging. The use of eco-friendly machining settings is intended to diminish tool wear and enhance the quality of the machined surface as well as the accuracy of the machined components. Adapting to the aforementioned factors for cold-forming dies is a pivotal issue. In this study, the machinability of tempered JIS SKD11 steel was analyzed under dry, MQL, cryogenic cooling with liquid nitrogen (LN₂), and liquid carbon dioxide (LCO₂) machining settings during open slot milling operations with varying input parameters, including cutting speeds and cutting feeds. An in-depth evaluation of output responses, including tool wear, surface roughness, cutting temperature in the cutting zone, and microhardness of the machined surface, was also conducted. The findings unveiled that the flank wear of the cutters and surface roughness of the machined surfaces obtained minimum values of 0.22 mm and 0.197 µm, respectively, during open slot milling operations at a cutting speed of 100 m/min and a cutting feed of 204 mm/min under cryogenic cooling with liquid carbon dioxide (LCO₂). The findings from this study suggest that employing cryogenic cooling with LCO₂ could serve as a viable substitute for dry, MQL, and cryogenic cooling with LN₂ methods to enhance the machinability of hardened JIS SKD11 steel. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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19 pages, 8898 KiB

Open AccessArticle

Simulation of Preload Relaxation of Bolted Joint Structures under Transverse Loading

by Yilong Liu, Min Zhu, Xiaohan Lu, Shengao Wang and Ziwei Li

Coatings 2024, 14(5), 538; https://doi.org/10.3390/coatings14050538 - 26 Apr 2024

Cited by 1 | Viewed by 1436

Abstract

In this study, based on the Iwan model, the connection interface of the bolted joint structure subjected to lateral loads was simulated and comparatively analyzed. Commercial finite element software was used to model the bolted joint structure. Monotonic lateral loads and cyclic displacement loads were applied to the model. The changes in the preload force of the bolted connection structure, as well as the changes in the sticking zone and stress state of the connection interface, were analyzed, and the loading results of monotonic load and cyclic displacement load were compared. The results show that the contact interface stress decreases with the increase in displacement load, and this increase is also a nonlinear relationship, which is approximately in phase with the trend of the contact surface slip curve. The amount of contact surface stress loss and the amount of preload loss are not directly related to the magnitude of the initial preload, regardless of the loading conditions. The contact surface is also circular under any form of displacement loading, whether it is stressed or slipped. The amount of preload loss is proportional to the amount of bolt compression for that variable. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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28 pages, 17850 KiB

Open AccessArticle

Abrasive Wear Resistance and Tribological Characteristics of Pulsed Hard Anodized Layers on Aluminum Alloy 1011 in Tribocontact with Steel and Ceramics in Various Lubricants

by Mykhailo Student, Iryna Pohrelyuk, Juozas Padgurskas, Raimundas Rukuiža, Volodymyr Hvozdets’kyi, Khrystyna Zadorozhna, Halyna Veselivska, Oleksandra Student and Oleh Tkachuk

Coatings 2023, 13(11), 1883; https://doi.org/10.3390/coatings13111883 - 2 Nov 2023

Cited by 2 | Viewed by 2038

Abstract

Based on the analysis of known methods of surface hardening of aluminum alloys (chromium plating, plasma electrolytic oxidation, hard anodizing), the prospects for pulsed hard anodizing are shown both for improving the functional characteristics of alloys and for large-scale implementation of this method. The purpose of this work is to show the possibility of pulsed hard anodizing to improve the serviceability of low-strength aluminum alloy 1011 under conditions of abrasive and sliding wear. The influence of the pulsed anodizing temperature on the phase-structural state of the synthesized layers, their abrasive wear resistance, and tribological characteristics in various lubricants were established, and the mechanism of wear of these layers was proposed. It is shown that with an increase in the temperature of pulsed anodizing, the wear resistance of the synthesized layers increases, and their abrasive wear resistance decreases. The negative effect of lubricating media on the wear resistance of the synthesized layers compared to tests under dry conditions was shown, and an explanation for this phenomenon is proposed. A significant (up to 40 times) increase in wear resistance in dry friction of anodized low-strength aluminum alloy 1011 compared to high-strength aluminum alloy 1050 was shown. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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14 pages, 4760 KiB

Open AccessArticle

Improving Wear Resistance of Highly Porous Titanium by Surface Engineering Methods

by Serhii Lavrys, Iryna Pohrelyuk, Juozas Padgurskas and Khrystyna Shliakhetka

Coatings 2023, 13(10), 1714; https://doi.org/10.3390/coatings13101714 - 29 Sep 2023

Cited by 3 | Viewed by 1719

Abstract

The wear resistance of highly porous titanium in the tribo-pair with bronze under boundary lubrication condition was investigated. According to analyses of worn surfaces of highly porous titanium, it was shown that the main reason of poor wear resistance were subsurface pores that led to nucleation of micro-cracks in the subsurface layer and thereby intensified fatigue (delamination) wear. For improvement of wear resistance of highly porous titanium, the surface engineering methods, such as deformation (ball burnishing, BB), diffusion (gas nitriding, GN), and their combination—deformation–diffusion treatment (DDT), were considered. It was shown that surface hardening of highly porous titanium by BB, GN, and DDT reduces the weight wear intensity and the friction coefficient of the tribo-pairs by 1.4, 3.5, 4.0 and 1.8, 2.3, 3.2 times, respectively. Such an improvement in the tribological properties of highly porous titanium after surface hardening is explained by changes in the main wear mechanism of the tribo-pairs from adhesive and fatigue to abrasive. The highest wear resistance of highly porous titanium was observed after surface deformation–diffusion treatment, as this treatment provides a combination of the positive effects of both ball burnishing (closing of surface pores) and nitriding (formation of a surface chemically inert and hard nitride layer). Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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21 pages, 10389 KiB

Open AccessArticle

Analysis of the Distortion of the Bearing Rings after Quenching

by Xusheng Li, Dongying Ju, Jianting Cao and Kousuke Ishikawa

Coatings 2023, 13(7), 1190; https://doi.org/10.3390/coatings13071190 - 2 Jul 2023

Cited by 1 | Viewed by 1782

Abstract

Bearings are usually used at high-speed and high-load conditions, so the bearing sleeve must be able to withstand large contact stress, which requires heat treatment. However, during the quenching process of the bearing sleeve, a vapor film is formed on the surface. Since the vapor film is not uniform along the axial direction during the process of boiling and breaking, it will cause uneven distortion of the bearing sleeve. This uneven distortion will cause the outer ring of the bearing to have elliptical distortion after heat treatment. However, the mechanism of this problem and how to reduce the elliptical distortion has not been completely solved. In this paper, two points on the inner wall and outer wall of the bearing sleeve in the orthogonal direction are measured by means of experiments, and the mechanism of the ellipticity distortion during the quenching process is revealed. Additionally, through its horizontal placement, oblique placement, and vertical placement, the cooling curve and cooling rate curve changes in the process of entering the quenching agent are studied; based on the cooling curve, the heat transfer coefficient of the bearing sleeve during quenching is obtained by the heat transfer equation. Input the heat transfer coefficient into the CAE heat treatment simulation software COSMAP, according to the Metallo-Thermo-Mechanics theory and the method of multi-field coupling, simulating the quenching process of GCr15 and 16MnCr5 materials. By comparison, the ellipticity value of the bearing placed at a 45° angle is smaller than that of the horizontally and vertically placed bearings, with the 16MnCr5 material having the smallest ellipticity value of 0.00016. The simulation results verified the distortion mechanism of the bearing sleeve during the quenching process and how to reduce the solution of elliptical distortion. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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16 pages, 2150 KiB

Open AccessArticle

Applicability Analysis of Nickel Steel Plate Friction Coefficient Model Based on Fractal Theory

by Min Zhu, Xiaohan Lu, Haiyan Li, Hongjun Cao and Fei Wu

Coatings 2023, 13(6), 1096; https://doi.org/10.3390/coatings13061096 - 13 Jun 2023

Cited by 2 | Viewed by 1476

Abstract

In the field of aerospace, weapons and other complex assembly, there are more than 50 factors affecting the performance degradation of joint structures, among which the friction coefficient is the main factor. Nickel steel is widely used in large complex equipment due to its advantages of high strength. Therefore, this paper first establishes a theoretical model of friction coefficient based on fractal theory. Secondly, the friction coefficient experiment was carried out to measure the friction coefficient of nickel steel plates with different roughness under different normal loads. Finally, the experimental results are compared with the theoretical results, and the accuracy and error analysis of the model is carried out. The results show that the friction coefficient increases with the increase in roughness. When the normal load is greater than 50 kg, the friction coefficient gradually tends to be stable. The error of identification results of correction factor a was all within 5%. The error between theoretical model prediction and experimental data is 6%–15%, which indicates that the calculation of the friction coefficient has high accuracy. The results of this study can provide data and theoretical support for the friction coefficient evaluation of nickel steel plate joint structures, and contribute to the health detection and reliability evaluation of nickel steel plate joint structures. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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Review

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29 pages, 5089 KiB

Open AccessReview

A Review of Cross-Scale Theoretical Contact Models for Bolted Joints Interfaces

by Yilong Liu, Min Zhu, Xiaohan Lu, Shengao Wang and Ziwei Li

Coatings 2024, 14(5), 539; https://doi.org/10.3390/coatings14050539 - 26 Apr 2024

Cited by 2 | Viewed by 1517

Abstract

Bolted joints structures are critical fastening components widely used in mechanical equipment. Under long-term loading conditions, the bolted joints interface generates strong nonlinearities within the system. The nonlinear stiffness inside the bolt leads to changes in the stiffness of the whole system. This affects the dynamic characteristics of the whole system. It brings challenges and difficulties to the performance prediction and reliability assessment of the equipment. A cross-scale theoretical model study based on the microscopic contact mechanism can provide a more comprehensive understanding and cognition of the degradation behavior of bolted joints interfaces. The current development status and deformation process of asperity models are summarized. The research progress of statistical summation model and contact fractal model based on microscopic contact mechanism is analyzed. The experimental methods for parameter identification of connection interfaces are reviewed. The study of numerical modelling of bolted joints structures from the surface contact mechanism is briefly described. Future research directions for cross-scale modelling of bolted joints structures are outlined. Full article

(This article belongs to the Special Issue Friction and Wear Behaviors in Mechanical Engineering)

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