Porous materials impregnated with lubricants can be used in conditions where limited lubricant is desirable. In this work, three porous polyimides (PPI) with different densities were prepared. Polyalphaolefin (PAO) impregnated PPI (iPPI) discs were rubbed against steel and sapphire balls. In operando observations of the iPPI–sapphire contacts show that oil is released under an applied load, forming a meniscus around contacts. Cavitation at the outlet is created at high sliding speeds. The amount of released oil increases with increasing PPI porosity. Contact moduli, E^*, estimated based on the actual contact size show that trapped oil in iPPIs contributes to load support. At higher speeds, tribological rehydration of the contact occurs in low density iPPI, with that E^* rises with speed. For high density PPIs, high speeds give a constantly high E^* which is limited by the viscoelastic properties of the PPI network and possibly the rate of oil exudation. Friction of iPPI–steel contacts is governed by the mechanical properties of the PPI, the flow of the lubricant, and the roughness of the PPI surfaces. For low- and medium-density (highly porous, high roughness) PPIs, large amount of oil is released, and lubrication is mainly via lubricant restricted in the contact in the pores and possibly tribological rehydration. For high density (low porosity) PPI, with lower roughness, hydrodynamic lubrication is achieved which gives the lowest friction. Our results show that polymeric porous materials for effective lubrication require the optimization of its surface roughness, stiffness, oil flow, and oil retentions.

Friction modifiers (FMs) are surface-active additives added to base fluids to reduce friction between rubbing surfaces. Their effectiveness depends on their interactions with rubbing surfaces and may be mitigated by the choice of the base fluid. In this work, the performance of an imidazolium ionic liquid (ImIL) additive in polyethylene-glycol (PEG) and 1,4-butanediol for lubricating steel/steel and diamond-like-carbon/diamond-like carbon (DLC–DLC) contacts were investigated. ImIL-containing PEG reduces friction more effectively in steel–steel than DLC–DLC contacts. In contrast, adding ImIL in 1,4-butanediol results in an increase in friction in steel–steel contacts. Results from the Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), and focused ion beam-transmission electron microscopy (FIB-TEM) reveal that a surface film is formed on steel during rubbing in ImIL-containing PEG. This film consists of two layers. The top layer is composed of amorphous carbon and are easily removed during rubbing. The bottom layer, which contains iron oxide and nitride compound, adheres strongly on the steel surface. This film maintains its effectiveness in a steel–steel contact even after ImIL additives are depleted. Such film is not observed in 1,4-butanediol where the adsorption of ImIL is hindered, as suggested by the quartz crystal microbalance (QCM) measurements. No benefit is observed when the base fluid on its own is sufficiently lubricious, as in the case of DLC surfaces.

This work provides fundamental insights on how compatibilities among base fluid, FM, and rubbing surface affect the performance of IL as surface active additives. It reveals the structure of an ionic liquid (IL) surface film, which is effective and durable. The knowledge is useful for guiding future IL additive development.