Advancing self‐lubricating technology: Selective laser sintering molding assisted development of copper‐based polytetrafluoroethylene /graphite composites

Abstract This study introduces an innovative technique for the fabrication of copper‐based polytetrafluoroethylene (PTFE)/graphite self‐lubricating composites. By harnessing the exceptional capabilities of selective laser sintering (SLS), we efficiently create three‐dimensional, continuous, and porous graphite preforms. Following this, the composite is formed through a combination of electroplating and vacuum extrusion methods. Subsequently, PTFE was vacuum impregnated into the microporous structure of the graphite preforms, and the composites were obtained through freeze‐drying, plasticizing, and machining processes. The resulting copper‐based PTFE/graphite self‐lubricating composites exhibit an exceptional blend of properties. Notably, there is a significant reduction in the average coefficient of friction, dropping from 0.14 to 0.02, and a marked decrease in the wear rate, from 1.358 × 10 −5 to 1.109 × 10 −5 mm 3 /N·m, as compared to graphite as a standalone lubricant. This represents a substantial improvement in performance, underscoring the effectiveness of the proposed fabrication method. Highlights The porous graphite with controllable shape distribution was prepared. Surface copper plating improves surface bonding. Controllable copper matrix composites with double lubricant were prepared. The average friction coefficient is as low as 0.02.