Intermetallic compounds are increasingly being expected to utilize in tribological environments, but to date the works are hindered by insufficient ductility at low and medium temperature. This paper presents a novel multiphase intermetallic alloy with the chemical composition of Mo-40Ni-13Si (at.%). Microstructure characterization reveals that a certain amount of ductile Mo phases formed during the solidification process of ternary Mo-Ni-Si alloy melt, which is undoubtedly beneficial to the ductility improvement of intermetallic alloy. Tribological properties of the designed alloy, including wear resistance, friction coefficient and metallic tribological compatibility, were evaluated under dry sliding wear test conditions at room temperature. Results suggested that the multiphase alloy possesses an excellent property for room-temperature wear applications, which is attributed to the unique microstructural features and thereby good combination in hardness and ductility. The corresponding wear mechanism is also reported by observing the worn surface, subsurface and wear debris of alloy, which to be found is soft abrasive wear.

In this study, 10%PTFE/PEEK blend were modified by potassium titanate whisker (PTW) and chopped glass fiber (GF), respectively. The blends were prepared by three-screw extruder. Through the investigation of thermal stability, tribological properties, mechanical properties and rheological behavior, the effects of reinforcing agents were determined. The results illustrated that the mechanical properties of 10%PTFE/PEEK blend can be dramatically improved by adding reinforcing agent of PTW or GF, and the reinforcing effect of GF was especially obvious. As for tribological properties, 1% addition was the best proportion. The friction coefficient and wear rate of the blend with 1% PTW were 0.283 and 4.97 × 10^-6 mm³/N · m, which decreased by 7.2% and 21% compared with those of the blend without reinforcing agent.

The application of metal-matrix composite coatings for protecting and improving the service life of sliding components has demonstrated to have the potentials of meeting the requirements of a diverse range of engineering industries. Recently, a significant body of research has been devoted to study the mechanical and tribological performance of dispersion-strengthened MCrAlY coatings. These coatings belong to a class of emerging wear-resistant materials, offering improved properties and being considered as promising candidates for the protection of engineering structural materials exposed to tribological damage, especially at elevated temperature regimes. This paper attempts to comprehensively review the different reinforcements used in the processing of MCrAlY-based alloys and how they influence the mechanical and tribological properties of the corresponding coatings. Further, the major fabrication techniques together with their benefits and challenges are also reviewed. Discussion on the failure mechanisms of these coatings as well as the main determining factors are also included. In addition, a comprehensive survey of studies and investigations in recent times are summarized and elaborated to further substantiate the review.

The Planetary Roller Screw Mechanisms (PRSMs), alongside Ball Screw Mechanisms (BSMs) and Electromechanical Actuators (EMAs), occupies a pivotal role in advancing the precision and efficiency of various industrial applications, including aerospace, automotive, and high-precision machining tools. Despite their critical advantages such as high load capacity, superior precision, and extended lifespan, the deployment of PRSMs in complex operational conditions reveals a landscape rife with challenges and opportunities for further research. This comprehensive review endeavors to dissect the multifaceted aspects of PRSMs, focusing on their mechanics and dynamics, tribology and thermal behavior, and the paramount importance of reliability and condition monitoring. By synthesizing current research findings, this paper highlights the significant advancements in understanding the static and dynamic characteristics of PRSMs, the intricate interplay between lubrication conditions and wear mechanisms, and the critical role of thermal effects on operational performance. Moreover, it delves into the dynamic models that address the impact of manufacturing imperfections, such as waviness and defects, on the reliability of these mechanisms. Despite the strides made, the review identifies critical gaps in the existing literature, particularly under conditions of extreme temperatures, large deformations, and multifaceted loads, advocating for a holistic approach to research. By proposing integrated thermo-mechanical models and emphasizing the need for empirical validations, this paper outlines a roadmap for future studies aimed at facilitating the development of more robust and reliable PRSMs, capable of meeting the demands of complex operational scenarios and advancing the field of high-precision applications in aerospace, robotics, and beyond.

The lack of knowledge on the link between the manufacturing process and performances constitutes a major issue of brake lining development. This study focuses on the effect of mixing duration on properties and tribological behavior of organic friction composite materials. The adopted methodology is based on efficient simplified formulations to limit synergic effects by the reduction of number and size distribution of constituents. Microstructural characteristics are analyzed and correlated to thermo physical and mechanical properties. Wear mechanisms and tribological behavior are studied in relation with the given microstructure and material properties. In the elaboration process, mixing duration has an impact on particle distribution and fibre arrangement. Distribution and size of fibre entanglements are found to cluster carbonaceous particles, which creates bulk thermal bridges improving thermal conductivity. Moreover, rockwool fibre arrangements affect density, porosity and thermo-physical properties. In addition, mixing duration disrupts cohesion of fibre bundles with the matrix, affecting compressive modulus and wear behaviour. This microstructural defect fosters an abundant third-body source flow, which results in a high wear flow. Porosities induced by fibre entanglements, presenting large and irregular size and distribution on the friction surface, lead to a low wear resistance and change the stability of friction.

The study of the tribological behavior of the braking system in auto vehicles requires knowing the characteristics of the material in contact and, in the work process, for the friction pair, brake disc-pads. Materials structural analysis is necessary because the wear process depends on the friction pair chemical composition, and brake disk-pads, respectively on the work process parameters (pressing force, rotational speed, traffic conditions, etc.). The material of the brake discs is generally the same gray cast iron, but the brake pads can be semi-metallic (particles of steel, copper, brass, and graphite, all united with a special resin), organic materials (particles of rubber, glass, and kevlar all joined with the help of a resin), composite materials that contain different constituents and ceramic materials (rarely have small copper particles). Therefore, the purpose of the paper is to know the crystalline structure and the mechanical properties of the brake pad materials, through specific studies and analyses, with important implications on the friction and wear behavior.

Advanced Nano structural hard coatings are thin materials films that range in thickness from a few nanometers to a few micrometers and are applied to different surfaces to increase their hardness and wear resistance. Physical vapor deposition (PVD) or chemical vapor deposition (CVD) methods are frequently used to deposit these coatings. These coating’s distinctive characteristics result from their microstructure, which is made up of material columns or grains with a diameter of only a few nanometers. Increased hardness, higher wear resistance, and improved tribological properties result from these short dimensions. In applications with significant wear and/or high contact pressures, such as cutting tools, bearings, and engine parts, the usage of sophisticated Nano structural hard coatings is crucial. Advanced Nano structural hard coatings include, 1. Amorphous carbon coatings with high hardness, low friction, and exceptional wear resistance are known as diamond-like carbon (DLC) coatings. DLC coatings are frequently used in a variety of industries, including the automotive, aerospace, and biomedical ones. 2. Coatings made of titanium nitride (TiN): These metallic coatings have high hardness and wear resistance. Cutting tool, machining, and aerospace industries frequently use TiN coatings. 3. Chromium nitride (CrN) coatings: These coatings have great corrosion resistance, good wear resistance, and high hardness. Cutting tools, gears, and bearings are just a few of the objects that use CrN coatings. 4. Tungsten carbide (WC) coatings: These coatings, which have a high degree of hardness and wear resistance, are frequently employed in cutting tools and other applications that require wear resistance. Advanced Nano structural hard coatings provide many advantages over conventional coatings, including better hardness, increased wear resistance, and improved tribological qualities. The automotive, aerospace, and biomedical industries are just a few that could use these coatings. In this paper the author will explain about the design synthesis and applications of advanced Nano structural hard coating in aerospace and automotive applications.

Steel surface protection with hard coatings is essential in the metalworking industry, yet developing high-performance hard coatings still remains a challenge. Quaternary nitride coatings, particularly TiAlSiN, have been extensively studied, but commercial TiAlSiN coatings vary widely, and there is a lack of consistent data. This study presents findings on the development and evaluation of TiAlSiN and TiAlSiN/TiN thin films, with an 800 nm thick TiAlSiN top coating and a 100 nm thick TiN mid-coating. The films were deposited on C120 tool steel discs via reactive DC magnetron sputtering. Ti and TiAlSi 75–20–5 (at.%) disc-shaped targets (50.8 mm diameter × 6.3 mm thickness), fabricated by our team through spark plasma sintering, were used for the sputtering process. Coatings were grown on smooth steel substrates heated to 300 °C, resulting in a uniform micro-structure with nanoparticles of globular (TiN) or pyramidal shape (TiAlSiN), as evidenced by SEM analysis. Nanoindentation tests showed superior mechanical properties for all coatings compared to the steel substrate. Micro-scratch tests indicated better scratch resistance for TiAlSiN/TiN bilayer (BL) coatings than for TiAlSiN single-layer (SL) coatings. Electrochemical impedance spectroscopy tests in a 3.5 wt.% NaCl solution revealed that the BL coatings demonstrated superior corrosion resistance compared to the SL coatings, even after thermal aging at 800 °C for 1 hour. The superior properties of the synthesized TiAlSiN/TiN films recommend them as protective coatings for tool steel surfaces.

Magnesium and Aluminum alloys continue to be important in the context of modern and lightweight technologies. With the advancement of additive manufacturing (AM), components can be produced directly in a net shape, widen up the usage of magnesium and aluminum alloys as well as holding new ideas for the application of unique physical structures made feasible by 3D printing. Laser-based approach, one of the metal additive manufacturing (AM) methods, enables the formation of arbitrary 3D structures. With promising findings, research in this area is advancing quickly, bringing up a variety of potential applications in both the scientific and industrial sectors. Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives like reduced part numbers, greater functionality, and lightweight, among others. AM has the ability to meet demands by lowering costs and speeding up the manufacturing process. Due to their popularity in numerous high-value applications, aluminum, and magnesium alloys are one of the key material systems being researched in the laser-based additive manufacturing approaches. The review here aims to comprehensively examine the additive manufacturing of magnesium and aluminum alloys, highlighting the influence of the laser-based additive manufacturing approach on the mechanical characteristics, microstructure, and tribological performance of magnesium and aluminum alloys.

One of the modern methods of improving operating characteristics of titanium and titanium-based alloys under conditions of friction and increased contact loads is the method of ion-plasma nitriding. The effect of nitriding of VT5 alloy (Al 4,5-6,7 %, V to 1,2 %, Mo to 0,8 % − analogue 3.7115) in the plasma of a glow discharge excited in a hollow cathode on its tribological characteristics in pairs with different materials in T-1 fuel and under dry friction conditions has been studied. For research and tribological tests, samples of VT5 alloy were nitrided in the plasma of a glow discharge excited in a hollow cathode at a temperature of 975 ± 15°C and a pressure of 58 ± 2 PA in a nitrogen-argon gas mixture with a nitrogen content of 78 %. Studies of samples of VT5 alloy after nitriding showed that the surface roughness Ra was in the range of 0.58-0.64, and the surface hardness HV5 was 525 ± 20 kgf/mm² at a base hardness of 325 ± 15 kgf/mm². Tribological tests were performed on a friction machine 2070 SMT-1 according to the scheme "cube - roller". Tests under conditions of friction with oil were performed at a load of 200 N. The sliding speed during the tests was 1.3 m/s, the test time was 75 sec. The test under dry friction conditions was carried out at a load of 100 N and a sliding speed of 0.785 m/s, the test time was 30 minutes. Low wear ability in relation to the nitrided titanium alloy VT5 (<2.4x10^-4 mm³/s), as well as friction coefficients at the level of 0.08 to 0.12 in the order of their growth had bronze VB-23NTS (Pd 18–22 %, Ni 3–4 %, Zn 3–4 %, Sb 3–4 %, P 0.15–0.3) r.O10C2N3, VB-24 (Sb 4.7–6, 2 %, P 0.4–0.9), steel 1.3505, cast iron GGG80, cemented steel 20Cr3MoWV.

Poly-ether-ether ketone (PEEK) is a great potential thermoplastic in industry and medical treatment and health. In this work, the PEEK/GO and PEEK/MoS2 composites were prepared by a novel hot isostatic pressing method. The addition of GO alters the tribological behaviours mechanism, fatigue wear mechanism is predominant to PEEK/GO composites. However, the combination of abrasive and adhesive wear mechanisms is observed for PEEK/MoS2 composites and PEEK. The reason is the hardness and tensile strength of composites are increased with the appropriate addition of GO. The response time to stable friction state of PEEK/GO and PEEK/MoS2 composites reduces in compared with PEEK, which conduce to shorten running-in time, reduce energy consumption and improve the tribological performances of composites. The addition of GO and MoS2 can effectively decrease the friction coefficient and wear rate, and the optimal content of GO and MoS2 was 0.7 wt.% and 15 wt.%, respectively. The results indicate that PEEK/GO and PEEK/MoS2 are impressive composites that possess super tribological properties.

Experimental studies on the development of processes of obtaining ultradispersed metal-ceramic materials and coatings Mo-ZrO₂, Mo-Al₂O₃, W-ZrO₂, W-Al₂O₃ CVD by deposition from the gas phase in CO₂ process using low-temperature nonequilibrium plasma were carried out.The structure, microhardness, phase composition, and high-temperature annealing behavior of the materials were studied. It is shown that the choice of parameters of the deposition process and temperature annealing can be controlled by the distribution function of ultradispersed particles in the material and their sizes.High-temperature X-ray studies of "molecular" two-phase alloys Mo- Al₂O₃ and Mo- ZrO₂show that, depending on the elastic and thermal properties of the matrix materials and dispersed particles, the molybdenum matrix can be in an all-round tensed or all-round compressed state.In the study of the electro-physical characteristics of the two-phase disperse-strengthened alloys Mo- ZrO₂, Mo- Al₂O₃, W- ZrO₂, W- Al₂O₃ it has been established that in the region of temperatures 1023...1273K anomalous changes of specific electrical resistance and instability of thermal eddy in magnitude are observed apparently connected with the presence of internal stresses in material caused by ultradisperse particles.Theoretical aspects of the problem of increasing the carriers density in nanocomposite materials are reviewedTheoretical analysis of the effect of the ensemble of microparticles on the change of electron density in ultradisperse metal-ceramic materials is carried out. It is shown that the average values of the electron density in the matrix with the introduction of 1% of particles with a radius of 50 A increase by more than two orders of magnitude.The possibilities of creating ultradisperse compositions using radiation-plasma methods are considered.

Several challenges stand in the way of production of Metal Matrix Composites (MMCs) such as higher processing temperatures, particulate mixing, particulate-matrix interface bonding issues and ability to process into desired geometrical shapes. Although there are many literatures showing composites with single particulate reinforcements, the studies on composites with multiple reinforcing agents (hybrid composites) are found to be limited. Development of a hybrid particulate composite with optimized mechanical and tribological properties is very significant to suit modern engineering applications. In this study, Al-Si hypereutectic alloy (A390) is used as the matrix and Silicon Carbide (SiC) and Graphite (Gr) and Molybdenum di-Sulphide (MoS₂) are used as particulates. Particulate volume (wt%) is varied and sample test castings are made using squeeze casting process through stir casting processing route. The evaluation of mechanical properties indicates that presence of both the hard phase (SiC) and the soft phase has distinct effect on the properties of Hybrid Composite. Composite samples were characterized to understand the performance and to meet the tribological applications. Fractography study indicated an intra-granular brittle fracture for hybrid composites. Wear study shows that Hybrid MMCs has better tribological performance compared to that of A390 alloy.

The application of dry lubrication in rolling contacts is challenging due to wear. In previous studies graphene platelets applied as dry lubricants on the surfaces of angular contact ball bearings demonstrated superior properties. These specific bearings, experiencing both rolling and spinning motion, create more severe conditions for dry lubricants. The applied graphene platelets have a thickness of few graphene layers in the nm range and a diameter in the µm range. Such platelets can be produced by mechanical exfoliation from graphite. To delve deeper into the lubrication effects, investigations were carried out using a milli tribometer. In the tests, a fixed steel ball is sliding against an oscillating counterpart under defined load. During the measurements, the applied load and tangential forces on the ball are recorded to calculate the friction. In our case, a steel ball with a diameter of 6 mm was used against graphene-based films on flat bearing surfaces (axial bearing washer). Comparative investigations included nano graphite particles and fullerene as dry lubricants, in addition to graphene platelets of various staple thicknesses. To increase the adhesion of the films to the surfaces, a pre-rolling process was implemented. Afterwards, the friction on the compressed films was measured. The results indicate that the pre-rolling process effectively reduces the friction of the system. After testing, the surfaces underwent analysis using laser scanning microscopy to assess the formed films, wear, and material transfer. It has been demonstrated that the pre-rolling process leads to the formation of a very thin compacted film with surface protective properties. On the ball as counterpart, the graphene platelets generate a transfer film on the contacting surface.

New multilayer 3D nanocomposite wear-resistant ion-plasma hard and superhard coatings Avinit [(TiN-AlN)(Mo-Cr-V-Si)]_n have been developed.The introduction of additional alloying elements (Mo, Cr, V, Si) into the Ti-Al-N coating composition, which have a high affinity for nitrogen and are capable of forming strong nitride nanoparticles in the Ti-N and Al-N layers.This makes it possible to obtain hard and superhard hardening coatings.The metallographic and tribological studies carried out indicate the prospects of the developed multicomponent multilayer nano- and microstructured Avinit coatings for increasing wear resistance and reducing friction coefficients.This paper is devoted to the development and implementation of Avinit vacuum plasma technologies for strengthening cutting and forming tools to improve tool performance.Production tests of cutting tools with Avinit's developed multilayer wear-resistant ion-plasma coatings in production conditions at many large machine-building enterprises have shown their high efficiency.In serial production, the wear resistance of tools increases by 3 to 30 times, stamps by 5 to 100 times, and parts rubbing against abrasive materials by 10 to 100 times.Avinit's vacuum plasma technologies have been successfully implemented in production in the aggregate and engine building, transport engineering, and power engineering industries.Positive experience in applying multicomponent coatings has been gained not only when applying hardening coatings to manufactured cutting tools, but also after regrinding to regrindable carbide cutting tools from domestic and foreign manufacturers.

In this work, Al-Mo-B(CN) thin coatings were deposited by magnetron sputtering using composite metal-ceramic Al-Mo-B4C target. A metal-ceramic composite target for magnetron sputtering was fabricated by a robotic complex for detonation spraying of coatings equipped with a multi-chamber detonation accelerator. The powder composition (30Mo-30Al-40B4C) was sprayed onto the copper plate base of the composite target-cathode. The obtained cathode target with Al-Mo-B4C coating (thickness 280-300 μm) was used to deposit the Al-Mo-B(CN) coating (DC mode) on flat specimens of AISI 316 steels and silicon using equipment for magnetron sputtering UNICOAT 200. The Al-Mo-B4C coating has a lamella-type structure with inclusions of boron car-bide particles the elemental composition is evenly distributed in the material. The structure and morphology of coatings were studied using methods of optical, scanning electron microscopy (SEM), atomic force microscopy (AFM), X-ray analysis (XRD), and X-ray photoelectron spectros-copy (XPS). Mechanical and tribological properties of the Al-Mo-B(CN) thin coatings were determined using methods of nanoindentation, scratch testing, and tribological testing under fluid-free friction regime at room temperature. The Al-Mo-B(CN) coating (thickness ~ 1 μm) exhibited a dense uniform fine-grained structure with no columnar elements and were well-adherent to the substrates after deposition. Al-Mo-B(CN) coating has a amorphous structure. XPS analysis confirmed the formation of the MoB2 and AlN phase with an admixture of oxygen in the form of aluminum oxide, molybdenum oxide and boron oxide. Al-Mo-B(CN) coating possess hardness of 13 GPa, elasticity modulus of 114 GPa, elastic recovery of 45%, and friction coefficient of 0.8 against steel 100 Cr6 ball. The failure mode occurring in the tested coatings was fatigue and abrasive. The adhesion strength of Al-Mo-B(CN) coating amounted to about 11 N, and the failure mode was cohesive associated with plastic deformation and formation of fatigue cracks in the coating material.

Within the task of replacing bronze journal bearings with aluminum the processes taking part on friction surface of high-alloyed aluminum alloys working with steel are investigated. The surface and subsurface layer of experimental aluminum bearings were studied before and after tribological tests by scanning electron microscopy including energy-dispersive analysis. Both structural and composition changes in surface layer are shown. It has been revealed that secondary structures are formed on the surface during friction process and include all the chemical elements of the tribosystem which is a consequence of its self-organization. The interaction behavior of some chemical elements of tribological system is discussed.

(1) Predictive assessment of the performance characteristics of metal-polymer (MP) plain bearings at the design stage is necessary and important for engineering practice. They include bearing capacity, linear wear of the bushing, and bearing life. However, no method for their calculation has been developed. (2) The authors have created a generalized analytical method for the mathematical modeling of MP sliding bearings as a classical science-based method of contact mechanics of conformal cylindrical bodies with consideration of polymer bushing wear. (3) Contact problem of the theory of elasticity takes into account the significant difference in the elasticity characteristics of polymeric materials from those of steel: Young's modulus is 60...250 times smaller, Poisson's ratio is 1.27...1.37 times larger. The method has been used to study MP bearings with several common groups of tribopolymers used for bushings: PA, PTFE, PET, and PEEK. The maximum contact pressures and durability of dry friction bearings have been calculated taking into account the load, radial clearance, bushing thickness, elasticity characteristics of tribopolymers, their wear resistance, sliding friction coefficient, and type of tribopolymer materials. (4) The paper establishes quantitative and qualitative regularities of the influence of these factors on the maximum contact pressures and bearing durability.

One of the most important objectives of the studies worldwide is to improve the performance of automotive engines to reduce fuel consumption and environmental pollution. Accordingly, the principal motivation of this research study is improving the tribological behavior of the piston ring/cylinder liner interfaces as a promising and straightforward approach in automotive fuel economy and increasing engine durability using Al₂O₃ and TiO₂ nanomaterials as smart nano-lubricant additives that adapted to different operating conditions by replenishing mechanisms anti-friction and anti-wear in automotive engines.