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Researchers target superlubricity for sliding components

Plain bearings rank among the most widely used functional elements in mechanical and plant engineering. They operate in engines, gearboxes, pumps, and drive systems and directly influence the energy demand of entire machines. Today, sliding elements often consist of steel, bronze, or engineering plastics and operate with mineral oil-based lubricants.

With its new BioSlide research project, the Fraunhofer Institute for Material and Beam Technology IWS in Germany is investigating how sliding systems can be designed to be more sustainable and energy efficient, pursuing an alternative approach where renewable raw materials replace established materials while opening new tribological performance reserves. A key focus is on lubricants and superlubricity.

What Is superlubricity?
Superlubricity describes a state of extremely low friction where the coefficient of friction falls below 0.01. Moving a component along its contact surface, therefore, requires less than one percent of the normal force acting on it. Surfaces slide past each other almost without resistance, energy losses drop significantly, components heat up less, and wear decreases. Superlubricity significantly increases the efficiency of technical systems and can arise across different sliding systems via various mechanisms. Of particular interest -- and the focus of the project -- is superlubricity achieved with robust surfaces and lubricants that can be manufactured economically.

Superlubricity as core research topic
The BioSlide project centers on superlubricity, a tribological state with a coefficient of friction below 0.01 that significantly reduces friction losses. Components generate less heat, wear decreases, and energy consumption declines noticeably during operation. Fraunhofer IWS has researched superlubricity for several years and now transfers this expertise specifically to bio-based materials and lubricant systems.

"BioSlide links our superlubricity research with the pursuit of sustainable materials," says Dr. Stefan Makowski, group manager, Tribological Systems. "We examine whether bio-based alternatives can replace conventional materials in sliding systems and which opportunities bio-based lubricants offer for achieving extremely low friction."

A technological focus is on functional coatings made of tetrahedral amorphous carbon (ta-C). These coatings create smooth, wear-resistant surfaces and rank among the key enablers of superlubricity. Researchers can also apply these coatings to non-conductive substrates and use them without mechanical post-processing using the Laser-Arc process developed at Fraunhofer IWS in the 1990s and substantially improved since. It is an advanced physical vapor deposition (PVD) coating technology that combines a pulsed laser with a vacuum arc evaporation system. This capability brings bio-based plastics, wood fiber composites, and other renewable materials into focus as load-bearing elements in sliding systems for the first time.

Funding establishes new junior research group
German federal funding supports the establishment of this new research group at Fraunhofer IWS. Over four years, scientists and technical staff aim to jointly address how future tribological systems can conserve resources. At the end of last year, the institute founded the Tribological Systems group under the leadership of Dr. Makowski. In addition to scientific qualifications, the project funds two doctoral positions, building a long-term competence base at the institute. An advisory team from industry and international mentors supports the group.

The new group consolidates specialized infrastructure for tribological investigations. Tribometers capture extremely low friction values with precision and reproducibility. A bearing test rig measures friction and wear directly in plain bearings. Complementary analyses of materials, coatings, and lubricants enable a comprehensive understanding of interfacial processes. This equipment allows realistic evaluation of new concepts and supports their development toward application.

"With BioSlide, we deliberately build expertise that connects basic research with industrial questions," says Prof. Christoph Leyens, Institute Director of Fraunhofer IWS. "The funding allows us to address these topics in a structured way over several years."

Alongside scientific work, industrial applicability remains a central focus. BioSlide targets mechanical and plant engineering in particular, as well as applications with high demands on energy efficiency, reliability, and environmental compatibility. The junior research group welcomes industry partnerships and offers tribological testing and development services.

Learn more about BioSlide at https://www.iws.fraunhofer.de/en/technologyfields/thin-film-technology/tribological-systems/bioslide.html.

Learn more about Laser Arc Coating at https://www.iws.fraunhofer.de/en/technologyfields/thin-film-technology/tribological-functional-coatings/laser-arc-coating.html.

Source: Fraunhofer Institute for Material and Beam Technology IWS

Published August 2026

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