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<p>Self-lubricating coatings have emerged as a crucial technology in advanced surface engineering to address pervasive issues of friction and wear across diverse industrial sectors, including automotive, aerospace, energy, and manufacturing. Traditional liquid lubricants often fail under extreme conditions such as high temperature, vacuum, corrosive environments, or high mechanical loads, leading to increased maintenance costs, energy losses, and reduced component lifespan. In contrast, self-lubricating coatings incorporate solid lubricant phases (e.g., graphite, molybdenum disulfide (MoS₂), hexagonal boron nitride (h-BN), tungsten disulfide (WS₂), and fluorides) embedded within metal or ceramic matrices to form stable, low-friction tribofilms that significantly enhance durability and performance. This review systematically examines the material selection, microstructural design, and fabrication methods particularly laser cladding that enable the synthesis of high-performance self-lubricating coatings. Key advances in the dispersion of lubricious phases, optimization of laser processing parameters, and integration of hybrid composites are analyzed to illustrate their impact on friction reduction, wear resistance, and thermal stability. The tribological mechanisms governing these coatings are discussed in detail, highlighting the layered crystal structures of solid lubricants that facilitate easy interlayer shear via weak van der Waals forces, resulting in low coefficients of friction often below 0.2. Moreover, recent developments in surface texturing, ultrasonic-assisted cladding, and nanoscale reinforcement are explored as effective strategies to improve lubricant retention and microstructural homogeneity. The review consolidates experimental findings on microstructure-property relationships, wear modes, and environmental influences on performance, providing a comprehensive framework for the design and application of next-generation self-lubricating coatings. These coatings represent a transformative solution to reduce energy consumption, enhance machinery reliability, and promote environmental sustainability in critical industrial applications.</p>

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Characterization and wear behavior of Self-Lubricating coatings produced via laser cladding: a comprehensive review

  • 期刊论文

  • 发表日期：

    2025年10月28日

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  • Morteza Taheri,
  • Kourosh Shirvani

摘要

Self-lubricating coatings have emerged as a crucial technology in advanced surface engineering to address pervasive issues of friction and wear across diverse industrial sectors, including automotive, aerospace, energy, and manufacturing. Traditional liquid lubricants often fail under extreme conditions such as high temperature, vacuum, corrosive environments, or high mechanical loads, leading to increased maintenance costs, energy losses, and reduced component lifespan. In contrast, self-lubricating coatings incorporate solid lubricant phases (e.g., graphite, molybdenum disulfide (MoS₂), hexagonal boron nitride (h-BN), tungsten disulfide (WS₂), and fluorides) embedded within metal or ceramic matrices to form stable, low-friction tribofilms that significantly enhance durability and performance. This review systematically examines the material selection, microstructural design, and fabrication methods particularly laser cladding that enable the synthesis of high-performance self-lubricating coatings. Key advances in the dispersion of lubricious phases, optimization of laser processing parameters, and integration of hybrid composites are analyzed to illustrate their impact on friction reduction, wear resistance, and thermal stability. The tribological mechanisms governing these coatings are discussed in detail, highlighting the layered crystal structures of solid lubricants that facilitate easy interlayer shear via weak van der Waals forces, resulting in low coefficients of friction often below 0.2. Moreover, recent developments in surface texturing, ultrasonic-assisted cladding, and nanoscale reinforcement are explored as effective strategies to improve lubricant retention and microstructural homogeneity. The review consolidates experimental findings on microstructure-property relationships, wear modes, and environmental influences on performance, providing a comprehensive framework for the design and application of next-generation self-lubricating coatings. These coatings represent a transformative solution to reduce energy consumption, enhance machinery reliability, and promote environmental sustainability in critical industrial applications.