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<p>PSF@Oil microcapsules were prepared using a solvent evaporation method, and the effects of key process parameters on their formation were systematically examined through single-factor and orthogonal experimental design. For the average particle size and SEM characterization, the mechanism by which each factor affects the physical properties of the microcapsules&#xa0;was analyzed. The optimal synthesis conditions were identified as 30°C heating temperature, a composite surfactant system of 1 wt% PVA and 0.5 wt% gelatin, a shell to core mass ratio of 1:1, and a stirring rate of 850 r/min. Under these conditions, the microcapsules exhibited uniform spherical morphology with an average particle size of 36.7&#xa0;μm. Microcapsules with different mass fractions were then incorporated into an epoxy resin matrix to produce composite coatings. Tribological tests showed that the coating with 9 wt% microcapsules delivered the best performance, reducing the friction coefficient by 75.2% and the wear rate by 80.0% compared with the unmodified epoxy coating. The improvement is attributed to the rupture of microcapsules under shear and thermal stresses, which releases the encapsulated oil and promotes the formation of an in situ transfer film at the sliding interface. These results highlight the effectiveness of oil-loaded microcapsules in enhancing the self-lubricating performance of epoxy-based coatings, offering strong potential for advanced engineering applications.</p> Graphical abstract <p></p>

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Synthesis and optimization of microcapsules and tribological properties of epoxy resin composite coatings

  • 期刊论文

  • 发表日期：

    2026年7月22日

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  • Xiaoyi Wei,
  • Zhongliang Yang,
  • Zhiqiang Huang,
  • Lixiu Zhang,
  • Han Lu,
  • Zhenyu Yin,
  • Hongwei Bai

摘要

PSF@Oil microcapsules were prepared using a solvent evaporation method, and the effects of key process parameters on their formation were systematically examined through single-factor and orthogonal experimental design. For the average particle size and SEM characterization, the mechanism by which each factor affects the physical properties of the microcapsules was analyzed. The optimal synthesis conditions were identified as 30°C heating temperature, a composite surfactant system of 1 wt% PVA and 0.5 wt% gelatin, a shell to core mass ratio of 1:1, and a stirring rate of 850 r/min. Under these conditions, the microcapsules exhibited uniform spherical morphology with an average particle size of 36.7 μm. Microcapsules with different mass fractions were then incorporated into an epoxy resin matrix to produce composite coatings. Tribological tests showed that the coating with 9 wt% microcapsules delivered the best performance, reducing the friction coefficient by 75.2% and the wear rate by 80.0% compared with the unmodified epoxy coating. The improvement is attributed to the rupture of microcapsules under shear and thermal stresses, which releases the encapsulated oil and promotes the formation of an in situ transfer film at the sliding interface. These results highlight the effectiveness of oil-loaded microcapsules in enhancing the self-lubricating performance of epoxy-based coatings, offering strong potential for advanced engineering applications.

Graphical abstract