Supra-lubricated bearings for maximum energy efficiency and precision

Project description

Researchers from the four Fraunhofer Institutes IWM, IPA, IWS, and IKTS established a modular system consisting of various super-lubricating systems—ceramics, diamond, graphene, and carbon layers—in combination with sustainable lubricants. These well-matched material-lubricant pairings were then used to create super-lubricating bearings. With extremely low friction coefficients of < 0.01, new, virtually loss-free applications were developed across a wide range of systems.

Super-lubricated bearings allowed engineers to design drive systems for electric cars and e-bikes that were even lighter and had less friction, significantly increasing their range. The new generation of plain bearing systems also demonstrated advantages in robotic positioning systems: smooth gliding enabled previously unimagined precision. The energy sector benefited as well, with pumps featuring extremely low-friction plain bearings contributing to significant energy and CO₂ savings. To ensure successful transfer to industry, the consortium focused on simple, highly scalable plain bearing designs. Prototypes were tested with industry partners as part of the project.