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<p>Frictional losses account for nearly a quarter of global energy consumption, underscoring the urgent need for advanced self-lubricating materials that enhance energy efficiency throughout their entire life cycle, from manufacturing to end use. Solid lubricant films are limited by wear, whereas vacuum impregnation of sintered components provides sustained lubrication and tunable tribological properties. Here, a novel strategy for engineering low-alloy sintered steels with superior dry sliding performance via vacuum impregnation with MoS<sub>2</sub> and graphite is reported. While each lubricant is widely used, its combined impregnation into porous steels has not been previously explored. Tribological testing revealed a synergistic effect: samples impregnated with both lubricants achieved an exceptionally low coefficient of friction (0.056 ± 0.0052) under dry sliding conditions and wear rates on the order of 10<sup>−6</sup>&#xa0;mm<sup>3</sup>/N&#xa0;m, outperforming single-lubricant systems. Microstructural and Raman spectroscopy analyses demonstrated that the lamellar overlap of MoS<sub>2</sub> and graphite suppresses the formation of abrasive debris and MoO<sub>3</sub> oxidation, shifting the wear mechanisms from mild oxidative and abrasive wear toward stable plastic flow. Regarding the behavior of the solid lubricants, MoS<sub>2</sub> retained its bulk-like lubricity, while graphite experienced limited degradation (&lt; 20%) with a partial shift from sp<sup>2</sup> to sp<sup>3</sup> hybridization, enabling a durable, self-replenishing tribolayer. These results validate the sintering and impregnation route as a low-cost, highly effective way to improve tribological properties of mechanical components by taking advantage of the already existing pores on sintered materials.</p>

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Synergy Between MoS2 and Graphite in Vacuum-Impregnated Sintered Steels: Impact on Tribolayer Stability and Wear Mechanism Transitions

  • 期刊论文

  • 发表日期：

    2026年7月21日

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  • C. Madrid,
  • P. Martin,
  • N. Araya,
  • A. N. Klein,
  • R. Henriquez,
  • C. Aguilar

摘要

Frictional losses account for nearly a quarter of global energy consumption, underscoring the urgent need for advanced self-lubricating materials that enhance energy efficiency throughout their entire life cycle, from manufacturing to end use. Solid lubricant films are limited by wear, whereas vacuum impregnation of sintered components provides sustained lubrication and tunable tribological properties. Here, a novel strategy for engineering low-alloy sintered steels with superior dry sliding performance via vacuum impregnation with MoS2 and graphite is reported. While each lubricant is widely used, its combined impregnation into porous steels has not been previously explored. Tribological testing revealed a synergistic effect: samples impregnated with both lubricants achieved an exceptionally low coefficient of friction (0.056 ± 0.0052) under dry sliding conditions and wear rates on the order of 10−6 mm3/N m, outperforming single-lubricant systems. Microstructural and Raman spectroscopy analyses demonstrated that the lamellar overlap of MoS2 and graphite suppresses the formation of abrasive debris and MoO3 oxidation, shifting the wear mechanisms from mild oxidative and abrasive wear toward stable plastic flow. Regarding the behavior of the solid lubricants, MoS2 retained its bulk-like lubricity, while graphite experienced limited degradation (< 20%) with a partial shift from sp2 to sp3 hybridization, enabling a durable, self-replenishing tribolayer. These results validate the sintering and impregnation route as a low-cost, highly effective way to improve tribological properties of mechanical components by taking advantage of the already existing pores on sintered materials.