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<p>To address boundary lubrication failure and surface fatigue wear in guide bushings under complex operating conditions, this study proposes a synergistic strategy combining topology-optimized bionic surface textures and MAX phase-reinforced PTFE coatings, leveraging multi-scale structural and material design to enhance interfacial tribological performance. Inspired by the micro-protrusion architecture of mosquito compound eyes, bionic textures were designed via topology optimization and fabricated on Cr12MoV steel surfaces using pulsed laser machining, while curing the PTFE-Mo<sub>2</sub>Ga<sub>2</sub>C composite coating on the surface. Reciprocating friction tests demonstrated that increasing the optimized aperture size of textures reduced the average friction coefficient by 13.5% and wear rate by 39.1%. Transient structural simulations validated the stress redistribution capability of topology-optimized textures on curved bushing surfaces, showing a 41% reduction in peak contact stress compared to non-optimized designs. Mechanistic analysis revealed a dual lubrication mechanism, PTFE extruded at texture edges forms lubricating films retained within grooves for cyclic replenishment, and MAX phase microparticle released from micro-pores dynamically reduce friction through lamellar shear. This synergy enhances lubricant retention, promotes uniform stress distribution, and delays coating wear.</p>

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Synergistic Tribological Enhancement of Bushings Via Topology-Optimized Bionic Textures and MAX Phase-Reinforced PTFE Composite Coatings

  • 期刊论文

  • 发表日期：

    2025年9月12日

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  • Kunpeng Chen,
  • Qipeng Huang,
  • Xiaoliang Shi,
  • Weijie Zheng,
  • Haowen Qin,
  • Yuxuan Chen,
  • Haohui Li

摘要

To address boundary lubrication failure and surface fatigue wear in guide bushings under complex operating conditions, this study proposes a synergistic strategy combining topology-optimized bionic surface textures and MAX phase-reinforced PTFE coatings, leveraging multi-scale structural and material design to enhance interfacial tribological performance. Inspired by the micro-protrusion architecture of mosquito compound eyes, bionic textures were designed via topology optimization and fabricated on Cr12MoV steel surfaces using pulsed laser machining, while curing the PTFE-Mo2Ga2C composite coating on the surface. Reciprocating friction tests demonstrated that increasing the optimized aperture size of textures reduced the average friction coefficient by 13.5% and wear rate by 39.1%. Transient structural simulations validated the stress redistribution capability of topology-optimized textures on curved bushing surfaces, showing a 41% reduction in peak contact stress compared to non-optimized designs. Mechanistic analysis revealed a dual lubrication mechanism, PTFE extruded at texture edges forms lubricating films retained within grooves for cyclic replenishment, and MAX phase microparticle released from micro-pores dynamically reduce friction through lamellar shear. This synergy enhances lubricant retention, promotes uniform stress distribution, and delays coating wear.