Multi-Scale Surface Texturing in Tribology—Current Knowledge and Future Perspectives

Effect of Zonal Laser Texturing on Friction Reduction of Steel Elements in Lubricated Reciprocating Motion

During co-action between contact elements in reciprocating motion, different working conditions exist in outer and inner zones of stationary elements. Because the tribological effects of surface texturing depend on the operating conditions, various dimple patterns were created in the middle part of the steel disc and near the reversal points. The behaviors of variable dimple patterns were compared with those of uniform texturing and untexturing. It was found that the dimple patterns in the middle disc zone depended on the resistance to motion. The best tribological behavior was obtained for a pit area ratio of 13% and diameter of 0.4 mm in the inner zone, and pit area ratio of 3% and diameter of 0.2 mm in the outer zones. Low resistance to motion and the smallest friction variation of all tested sliding pairs were achieved. For the same pit area ratio of 13% in a disc of 0.4 mm, the dimple diameter behaved better than in the 0.2 mm diameter disc. The greatest decrease in the coefficient of friction of 85% compared to untextured sliding pair was achieved for uniform laser texturing with a pit area ratio of 13% and dimple diameter of 0.4 mm, when the normal load was 40 N and frequency of displacement was 20 Hz.

Simulation and Structural Analysis of a Flexible Coupling Bionic Desorption Mechanism Based on the Engineering Discrete Element Method

Soil adhesion is one of the important factors affecting the working stability and quality of agricultural machinery. The application of bionic non-smooth surfaces provides a novel idea for soil anti-adhesion. The parameters of sandy loam with 21% moisture content were calibrated by the Engineering Discrete Element Method (EDEM). The final simulated soil repose angle was highly consistent with the measured soil repose angle, and the obtained regression equation of the soil repose angle provides a numerical reference for the parameter calibration of different soils. By simulating the sinusoidal swing of a sandfish, it was found that the contact interface shows the phenomenon of stress concentration and periodic change, which reflects the effectiveness of flexible desorption and soil anti-adhesion. The moving resistance of the wedge with different wedge angles and different serrated structures was simulated. Finally, it was found that a 40° wedge with a high-tail sparse staggered serrated structure on the surface has the best drag reduction effect, and the drag reduction is about 10.73%.

Bioinspired and Multifunctional Tribological Materials for Sliding, Erosive, Machining, and Energy-Absorbing Conditions: A Review

Friction, wear, and the consequent energy dissipation pose significant challenges in systems with moving components, spanning various domains, including nanoelectromechanical systems (NEMS/MEMS) and bio-MEMS (microrobots), hip prostheses (biomaterials), offshore wind and hydro turbines, space vehicles, solar mirrors for photovoltaics, triboelectric generators, etc. Nature-inspired bionic surfaces offer valuable examples of effective texturing strategies, encompassing various geometric and topological approaches tailored to mitigate frictional effects and related functionalities in various scenarios. By employing biomimetic surface modifications, for example, roughness tailoring, multifunctionality of the system can be generated to efficiently reduce friction and wear, enhance load-bearing capacity, improve self-adaptiveness in different environments, improve chemical interactions, facilitate biological interactions, etc. However, the full potential of bioinspired texturing remains untapped due to the limited mechanistic understanding of functional aspects in tribological/biotribological settings. The current review extends to surface engineering and provides a comprehensive and critical assessment of bioinspired texturing that exhibits sustainable synergy between tribology and biology. The successful evolving examples from nature for surface/tribological solutions that can efficiently solve complex tribological problems in both dry and lubricated contact situations are comprehensively discussed. The review encompasses four major wear conditions: sliding, solid-particle erosion, machining or cutting, and impact (energy absorbing). Furthermore, it explores how topographies and their design parameters can provide tailored responses (multifunctionality) under specified tribological conditions. Additionally, an interdisciplinary perspective on the future potential of bioinspired materials and structures with enhanced wear resistance is presented.

Strategies in surface engineering for the regulation of microclimates in skin-medical product interactions

There is a growing number of personal healthcare devices that are in prolonged contact with the skin. The functionality of these products is linked to the interface formed by the contact between the medical apparatus and the skin. The interface can be characterised by its topology, compliance, and moisture and thermal regulating capabilities. Many devices are, however, described to have suboptimal and occlusive contacts, resulting in physiological unfavourable microclimates at the interface. The resulting poor management of moisture and temperature can impact the functionality and utility of the device and, in severe cases, lead to physical harm to the user. Being able to control the microclimate is therefore expected to limit medical-device related injuries and prevent associated skin complications. Surface engineering can modify and potentially enhance the regulation of the microclimate factors surrounding the interface between a product's surface and the skin. This review provides an overview of potential engineering solutions considering the needs for, and influences on, regulation of temperature and moisture by considering the skin-medical device interface as a system. These findings serve as a platform for the anticipated progress in the role of surface engineering for skin-device microclimate regulation.

Tailoring the Coefficient of Friction by Direct Laser Writing Surface Texturing

The modification of the surface topography at the micro- and nanoscale is a widely established as one of the best ways to engineering the surface of materials, to improve the tribological performances of materials in terms of load capacity and friction. The present paper reviews the state of the art on laser surface texturing by exploiting the technique of direct laser writing for tailoring the coefficient of friction, highlighting the effect of the textures' arrangement on the lubricated conformal and non-conformal contact behavior.

Surface Texturing of Cylinder Liners: A Review

The effect of cylinder liners on engine performance is substantial. Typically, the cylinder surfaces were plateau honed. However, recently additional dimples or grooves were created on them. This work discusses the tribological impacts of textured cylinder liner surfaces based on a review of the literature. The results of the experimental research obtained using test rigs and fired engines were critically reviewed. In addition, the results of the modeling are shown. Circular oil pockets and grooves perpendicular to the sliding direction of piston rings of small depths were typically used. Surface texturing of the cylinder liners governs lubrication between the cylinder liner and the piston ring by an increase in oil film thickness near the reversal points leading to reductions in friction force and wear and in the fired engine to a decrease in fuel consumption and to an increase in power or torque. The correct texturing pattern ensures a decrease in the oil consumption, blow-by, and emissions of the internal combustion engine compared to plateau-honed surfaces. Considerations of future challenges are also addressed. The volume of lubricant reservoir in surface topography, called oil capacity, should be a substantial parameter characterizing textured surfaces.

Effects of Operating Conditions and Pit Area Ratio on the Coefficient of Friction of Textured Assemblies in Lubricated Reciprocating Sliding

The experiment was carried out in a reciprocating lubricated conformal sliding contact between steel discs of the same hardness. The effects of disc surface texturing on the friction coefficient at various operating conditions (temperature, normal load, and frequency of oscillations) were studied. Under various conditions, surface texturing caused friction reductions of sliding pairs. The largest reduction was 4.6 times at a lower temperature and 2.5 times at a higher temperature. The effect of the pit area ratio on the friction reduction was visible at a higher temperature. The highest dimple density of 25% corresponded to a lower coefficient of friction than the smallest density of 9%. The sliding pair with a dimple density of 17% led to large variation of the friction force. At lower temperatures, the coefficients of friction were lower compared to tests at higher temperatures.

Effect of Graphene Sheets Embedded Carbon Films on the Fretting Wear Behaviors of Orthodontic Archwire-Bracket Contacts

Carbon films were fabricated on the orthodontic stainless steel archwires by using a custom-designed electron cyclotron resonance (ECR) plasma sputtering deposition system under electron irradiation with the variation of substrate bias voltages from +5 V to +50 V. Graphene sheets embedded carbon (GSEC) films were fabricated at a higher substrate bias voltage. The fretting friction and wear behaviors of the carbon film-coated archwires running against stainless steel brackets were evaluated by a home-built reciprocating sliding tribometer in artificial saliva environment. Stable and low friction coefficients of less than 0.10 were obtained with the increase of the GSEC film thickness and the introduction of the parallel micro-groove texture on the bracket slot surfaces. Particularly, the GSEC film did not wear out on the archwire after sliding against three-row micro-groove textured bracket for 10,000 times fretting tests; not only low friction coefficient (0.05) but also low wear rate (0.11 × 10^-6 mm³/Nm) of the GSEC film were achieved. The synergistic effects of the GSEC films deposited on the archwires and the micro-groove textures fabricated on the brackets contribute to the exceptional friction and wear behaviors of the archwire-bracket sliding contacts, suggesting great potential for the clinical orthodontic treatment applications.

Production and Properties of the Porous Layer Obtained by the Electrochemical Method on the Surface of Austenitic Steel

The growing demand for implants has seen increasing interest in the introduction of new technologies and surface modification methods of metal biomaterials. This research aimed to produce and characterize a porous layer grown on austenitic stainless steel 316L, obtained via the anodization process near the micro-arc oxidation, i.e., low voltage micro-arc oxidation (LVMAO). The discussed layer significantly influences the properties of metallic biomedical materials. The surface topography, layer thickness, surface roughness, pore diameter, elemental composition, crystal structure, and surface wettability were assessed for all anodized layers, together with the resultant corrosion resistance. Attention was paid to the influence of the process parameters that affect the specification of the produced layer. The obtained results showed surface development and different sized pores in the modified layers, as well as an increase in corrosion resistance in the Ringer’s solution.

Utilizing a Diffractive Focus Beam Shaper to Enhance Pattern Uniformity and Process Throughput during Direct Laser Interference Patterning

Uniform periodic microstructure formation over large areas is generally challenging in Direct Laser Interference Patterning (DLIP) due to the Gaussian laser beam intensity distribution inherent to most commercial laser sources. In this work, a diffractive fundamental beam-mode shaper (FBS) element is implemented in a four-beam DLIP optical setup to generate a square-shaped top-hat intensity distribution in the interference volume. The interference patterns produced by a standard configuration and the developed setup are measured and compared. In particular, the impact of both laser intensity distributions on process throughput as well as fill-factor is investigated by measuring the resulting microstructure height with height error over the structured surface. It is demonstrated that by utilizing top-hat-shaped interference patterns, it is possible to produce on average 44.8% deeper structures with up to 60% higher homogeneity at the same throughput. Moreover, the presented approach allows the production of microstructures with comparable height and homogeneity compared to the Gaussian intensity distribution with increased throughput of 53%.

The Tribological Adaptability for Ventral Scales of Dinodon rufozonatum in Dry/Wet/Rough Environments

The ventral scales of Dinodon rufozonatum were investigated to understand the outstanding tribological adaptability in various environments. The coefficient of friction (COF) of ventral scales was measured and changed with the contact conditions. It was discovered that the COF of scales under water-lubrication conditions (WLC) was larger than that under dry conditions (DC). More interestingly, the COF increased first and then decreased as the substrate roughness reduced. The abrasion marks on scales were then observed. The results indicated that the scales in DC wore more gently than that in WLC. Moreover, the degree of wear reduced with the decrease of substrate roughness. The frictional performance of ventral scales enabled the snakes to move more efficiently, quickly, and flexibly in multiple environments.

Surface Treatment and Bioinspired Coating for 3D-Printed Implants

Three-dimensional (3D) printing technology has developed rapidly and demonstrates great potential in biomedical applications. Although 3D printing techniques have good control over the macrostructure of metallic implants, the surface properties have superior control over the tissue response. By focusing on the types of surface treatments, the osseointegration activity of the bone-implant interface is enhanced. Therefore, this review paper aims to discuss the surface functionalities of metallic implants regarding their physical structure, chemical composition, and biological reaction through surface treatment and bioactive coating. The perspective on the current challenges and future directions for development of surface treatment on 3D-printed implants is also presented.

Additive Manufacturing of Tungsten Carbide Surfaces with Extreme Wear Resistivity

Steel surfaces have been coated with Co-based tungsten carbide (WC) in an additive printing process. This process leads to compact and extremely mechanically stable surfaces. We performed tribological measurements using WC counter bodies under dry conditions and severe mechanical load. Low coefficients of friction, even for rough surfaces, were found and the resulting wear rates were extraordinarily small, even when compared to high-quality PVD film with a similar composition. These findings suggest a wide field of application for this novel preparation process for wear-resistive surfaces.

Exploring the lubrication mechanisms of synovial fluids for joint longevity - A perspective

Synovial fluids are complex fluids responsible for the exceptional lubrication present in synovial joints. These fluids consist of various constituents, including hyaluronic acid, surface-active proteins (i.e., lubricin), surface-active phospholipids, as well as various other proteins such as human serum albumin and γ -globulin seric proteins, each of them playing an essential role in lubrication. Being the key to the most efficient biotribological systems, this article is intended to review the current understanding of the underlying lubrication mechanisms of the synovial fluids enables prospective usage in numerous applications, especially as a lubricant for hip and knee prosthetics in combatting osteoarthritis. Current research focuses on the determination of the role of proteins in prosthetic lubrication, optimal material combinations for prosthesis, and the effects of relevant physical variables in prosthetic lubrication. The characterization of prosthetic lubrication and wear mechanisms by synovial fluids represents a prominent challenge in tribological research, yet also an important hurdle to overcome towards optimal lubrication of articular prosthetics.

Recent Progress on Wear-Resistant Materials: Designs, Properties, and Applications

There has been tremendous interest in the development of different innovative wear-resistant materials, which can help to reduce energy losses resulted from friction and wear by ≈40% over the next 10-15 years. This paper provides a comprehensive review of the recent progress on designs, properties, and applications of wear-resistant materials, starting with an introduction of various advanced technologies for the fabrication of wear-resistant materials and anti-wear structures with their wear mechanisms. Typical strategies of surface engineering and matrix strengthening for the development of wear-resistant materials are then analyzed, focusing on the development of coatings, surface texturing, surface hardening, architecture, and the exploration of matrix compositions, microstructures, and reinforcements. Afterward, the relationship between the wear resistance of a material and its intrinsic properties including hardness, stiffness, strength, and cyclic plasticity is discussed with underlying mechanisms, such as the lattice distortion effect, bonding strength effect, grain size effect, precipitation effect, grain boundary effect, dislocation or twinning effect. A wide range of fundamental applications, specifically in aerospace components, automobile parts, wind turbines, micro-/nano-electromechanical systems, atomic force microscopes, and biomedical devices are highlighted. This review is concluded with prospects on challenges and future directions in this critical field.

A Digital Twin for Friction Prediction in Dynamic Rubber Applications with Surface Textures

Surface texturing is an effective method to reduce friction without the need to change materials. In this study, surface textures were transferred to rubber samples in the form of dimples, using a novel laser surface texturing (LST)—based texturing during moulding (TDM) production process, developed within the European Project MouldTex. The rubber samples were used to experimentally determine texture-induced friction variations, although, due to the complexity of manufacturing, only a limited amount was available. The tribological friction measurements were hence combined with an artificial intelligence (AI) technique, i.e., Reduced Order Modelling (ROM). ROM allows obtaining a virtual representation of reality through a set of numerical strategies for problem simplification. The ROM model was created to predict the friction outcome under different operating conditions and to find optimised dimple parameters, i.e., depth, diameter and distance, for friction reduction. Moreover, the ROM model was used to evaluate the impact on friction when manufacturing deviations on dimple dimensions were observed. These results enable industrial producers to improve the quality of their products by finding optimised textures and controlling nominal surface texture tolerances prior to the rubber components production.

Finite Element Modelling and Experimental Validation of Scratches on Textured Polymer Surfaces

Surface texturing is a common modification method for altering the surface properties of a material. Predicting the response of a textured surface to scratching is significant in surface texturing and material design. In this study, scratches on a thermoplastic material with textured surface are simulated and experimentally tested. The effect of texture on scratch resistance, surface visual appearance, surface deformation and material damage are investigated. Bruise spot scratches on textured surfaces are found at low scratch forces (<3 N) and their size at different scratch forces is approximately the same. There is a critical point between the bruise spot damage and the texture pattern damage caused by continuous scratching. Scratch resistance coefficients and an indentation depth-force pattern are revealed for two textured surfaces. A texture named "Texture CB" exhibits high effectiveness in enhancing scratch visibility resistance and can increase the scratch resistance by more than 40% at low scratch forces. The simulation method and the analysis of the power spectral density of the textured surface enable an accurate prediction of scratches.

Laser Microtextured Surfaces for Friction Reduction: Does the Pattern Matter?

Frictional performances of different textures, including axisymmetric and directional patterns, have been tested in the mixed and the hydrodynamic lubrication regimes. Experimental results, corroborated by numerical simulations, show that the leading parameter is the geometrical pattern void ratio since a large number of dimples offers, at low speed, a trap for debris whereas, at high speed, due to the flow expansion in each micro-hole, fosters a fluid pressure drop, the consequent insurgence of micro-cavitation and, ultimately, the reductions of the shear stresses. Furthermore, in this paper, it is shown that, by means of directional textures, equivalent hydrodynamic wedges can be built up, thus establishing different friction performances depending on the flow direction.

Performance and Accuracy of the Shifted Laser Surface Texturing Method

A shifted laser surface texturing method (sLST) was developed for the improvement of the production speed of functional surface textures to enable their industrial applicability. This paper compares the shifted method to classic methods using a practical texturing example, with a focus on delivering the highest processing speed. The accuracy of the texture is assessed by size and circularity measurements with the use of LabIR paint and by a depth profile measurement using a contact surface profiler. The heat accumulation temperature increase and laser usage efficiency were also calculated. The classic methods (path filling and hatch) performed well (deviation ≤ 5%) up to a certain scanning speed (0.15 and 0.7 m/s). For the shifted method, no scanning speed limit was identified within the maximum of the system (8 m/s). The depth profile shapes showed similar deviations (6% to 10%) for all methods. The shifted method in its burst variant achieved the highest processing speed (11 times faster, 146 mm²/min). The shifted method in its path filling variant achieved the highest processing efficiency per needed laser power (64 mm²/(min·W)), lowest heat accumulation temperature increase (3 K) and highest laser usage efficiency (99%). The advantages of the combination of the shifted method with GHz burst machining and the multispot approach were described.

Friction Reduction in Unidirectional Lubricated Sliding Due to Disc Surface Texturing

Surface texturing is an option of surface engineering resulting in reduction of friction due to the creation of isolated dimples or grooves on sliding surfaces. The purpose of this work is to find the effect of the groove bottom profiles on the reduction of the friction force. Investigations were conducted using an Optimol SRV5 tribotester equipped with a pin-on-disc module. A disc made of 42CrMo4 steel, with a 100 mm diameter acted as a sample. A counter-sample was made of the same material, however, its diameter was 20 mm. The sliding conditions were selected to be similar to those of a sliding crankpin bearing pad operating in a high-performance internal combustion engine. Surface texturing was found to be beneficial for a reduction in the friction coefficient up to 55% in comparison to the untextured disc. Tribological performances of discs with spiral groove patterns were better than those with a radial layout. In most cases the convergent profile of the groove bottom was superior to the dam shape.

Effects of Surface Modification by Means of Low-Temperature Plasma Nitriding on Wetting and Corrosion Behavior of Austenitic Stainless Steel

Low-temperature nitriding of austenitic stainless steels produces modified surface layers, consisting mainly of the S phase, which improve surface hardness and corrosion resistance. Because of the localized plastic deformations, owing to modified layer formation, and ion bombardment occurring during the process itself, this treatment produces also modifications of surface morphology and roughness, which can affect wettability and corrosion behavior. In this study the effects of plasma nitriding, performed using different treatment conditions, on the surface morphology and roughness, and thus on wettability and corrosion resistance, of AISI 202 specimens with different initial finishings (2D and polished finishing) were investigated. Different probe liquids, having both high (bi-distilled water and solution of 3.5% NaCl) and low (ethanol and rapeseed oil) surface tension, were employed for assessing the wetting behavior with the sessile drop method. The contact angle values for water increased markedly when nitriding was performed on polished samples, while this increase was smaller for 2D samples, and on selected specimens a hydrophobic behavior was observed. Very low contact angle values were registered using low surface tension liquids, suggesting an oleophilic behavior. Corrosion resistance in a 5% NaCl solution was assessed, and it depended on the characteristics of the nitrided specimens.

On Friction Reduction by Surface Modifications in the TEHL Cam/Tappet-Contact-Experimental and Numerical Studies

The overall energy efficiency of machine elements and engine components could be improved by using new technologies such as surface modifications. In the literature, surface engineering approaches like micro-texturing and the application of diamond-like carbon (DLC) coatings were frequently studied separately, with focus on a specific model contact and lubrication conditions. The contribution of the current study is to elucidate and compare the underlying friction reduction mechanisms of the aforementioned surface modifications in an application-orientated manner. The study applied the operating conditions of the thermo-elastohydrodynamically lubricated (TEHL) cam/tappet-contact of the valve train. Therefore, tribological cam/bucket tappet component Stribeck tests were used to determine the friction behavior of ultrashort pulse laser fabricated microtextures and PVD/PECVD deposited silicon-doped amorphous carbon coatings. Moreover, advanced surface characterization methods, as well as numerical TEHL tribo-simulations, were utilized to explore the mechanisms responsible for the observed tribological effects. The results showed that the DLC-coating could reduce the solid and fluid friction force in a wide range of lubrication regimes. Conversely, micro-texturing may reduce solid friction while increasing the fraction of fluid friction.