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Lubricant Sustainable Superlubrication for Sliding Systems

From Fraunhofer IWS | Translated by AI 3 min Reading Time

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Friction determines energy consumption, wear and the service life of technical systems. In the BioSlide research project, the Fraunhofer Institute for Material and Beam Technology IWS is investigating how sliding systems can be designed to be more sustainable and energy-efficient.

With the BioSlide research project, the Fraunhofer IWS is investigating how sliding systems can be designed to be more sustainable and energy-efficient. New materials can be tested in a particularly application-oriented manner on this plain bearing test stand.(Image: Fraunhofer IWS)
With the BioSlide research project, the Fraunhofer IWS is investigating how sliding systems can be designed to be more sustainable and energy-efficient. New materials can be tested in a particularly application-oriented manner on this plain bearing test stand.
(Image: Fraunhofer IWS)

Plain bearings are used in motors, gearboxes, pumps and drive systems and play a key role in determining the energy requirements of entire machines. Today, the sliding elements are often made of steel, bronze or engineering plastics and work with mineral oil-based lubricants. The BioSlide research project is pursuing an alternative approach: renewable raw materials are to replace established materials and at the same time open up new tribological performance reserves.

The project is being funded by the Federal Ministry of Research, Technology and Space (BMFTR) in the BioKreativ 4 program with around $3.6 million USD. Over a period of four years, scientists and technical staff will work together on the question of how tribological systems can be designed to conserve resources in the future. To this end, the institute established the "Tribological Systems" group under the leadership of Dr. Makowski at the end of 2025. In addition to the scientific qualification, the project finances two doctoral positions and thus creates a long-term competence base at the institute. The group is supported by an advisory team of companies and international mentors.

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Supremacy As A Central Research Topic

The project focuses on superlubricity. In this condition, the coefficient of friction is less than 0.01. Components heat up less, wear decreases and the energy requirement during operation is noticeably reduced. The Fraunhofer IWS has been researching superlubrication for several years and is now transferring this knowledge specifically to bio-based material and lubricant systems. "BioSlide combines our superlubrication research with the question of sustainable materials," says Dr. Stefan Makowski, Group Manager Tribological Systems. "We are investigating whether conventional materials in sliding systems can be replaced by bio-based alternatives and what opportunities bio-based lubricants offer for extremely low friction."

What does “superlubrication” mean?

Superlubrication describes a state of extremely low friction. The coefficient of friction is less than 0.01. This means that less than one percent of the normal force acting on a component is required to move it along its contact surface. Surfaces glide over one another with virtually no resistance, energy losses decrease significantly, components generate less heat, and wear is reduced. Superlubrication significantly increases the efficiency of technical systems and can arise in various sliding systems based on different mechanisms. Of particular interest—and the focus of this project—is superlubrication achieved using robust and economically manufacturable surfaces and lubricants.

New Material Combinations Through Coatings

The researchers have also focused on functional coatings made of tetrahedral amorphous carbon. These so-called ta-C coatings produce smooth, low-wear surfaces and are considered the key to superlubricity. Using the laser arc process developed at the Fraunhofer IWS, they can also be applied to non-conductive substrates and used without mechanical post-processing. As a result, bio-based plastics, wood fiber composites and other renewable materials are also coming into focus for the first time as load-bearing elements in sliding systems. The "Tribological Systems" group pools specialized infrastructure for tribological investigations. Tribometers record extremely low friction values precisely and reproducibly. A bearing test bench measures friction and wear directly in the plain bearing. Supplementary analyses of materials, coatings and lubricants enable a comprehensive understanding of interface processes. This equipment makes it possible to realistically evaluate new concepts and develop them for application. In addition to scientific work, the focus is on industrial connectivity. BioSlide particularly addresses mechanical and plant engineering as well as applications with high demands on energy efficiency, reliability and environmental compatibility. The junior research group is open to cooperation with industrial partners and offers tribological testing and development services.

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