Recent Developments in Self-Lubricating Thin-Film Coatings Deposited by a Sputtering Technique: A Critical Review of Their Synthesis, Properties, and Applications

In response to the demand for advanced materials in extreme environments, researchers have developed a variety of bulk and thin-film materials. One of the best-known processes for altering the mechanical and tribological properties of materials is surface engineering techniques. These involve various approaches to synthesize thin-film coatings, along with post-deposition treatments. The need for self-lubricating materials in extreme situations such as high-temperature applications, cryogenic temperatures, and vacuum systems has attracted the attention of researchers. They have fabricated several types of thin films using CVD and PVD techniques to meet this demand. Among the various techniques used for fabricating self-lubricating coatings, sputtering stands out as a special one. It contributes to developing smooth, homogeneous, and crack-free dense microstructures, which further enhance the coatings’ properties. This review explains the need for self-lubricating materials and the different techniques used to synthesize them. It discusses and summarizes the concept of synthesizing various types of self-lubricating films. It shows the different types of self-lubricating material systems, like transition metal-based nitrides and carbides, diamond-like carbon-based materials, and so on. This work also reflects the governing factors like the deposition temperature, doping elements, thickness of the film, deposition pressure, gas flow rate, etc., that influence the deposition results and, consequently, the properties of the film, as well as their advanced applications in different areas. This work reflects the self-lubricating properties of different kinds of films exposed to various environments in terms of their coefficient of friction and wear rate, emphasizing how the friction coefficient affects the wear rate.