Laser Surface Texturing for Tribological Applications: Mechanisms, Surface Engineering Strategies, and Application-Oriented Design

Abstract

Friction and wear are major factors affecting the efficiency and reliability of mechanical systems, leading to increasing interest in laser surface texturing (LST) for tribological surface engineering. This review summarizes the development of LST from conventional surface modification to multifunctional interface design and discusses the underlying process–structure–performance relationships. Different lubrication-dependent mechanisms, including micro-hydrodynamic pressure generation, wear debris entrapment, contact stress regulation, metallurgical strengthening, and wettability control, are analyzed under hydrodynamic, boundary, and dry sliding conditions. Representative processing technologies, including nanosecond, ultrafast, direct laser interference patterning (DLIP), and liquid-assisted laser processing, are compared in terms of fabrication precision, thermal effects, scalability, and tribological performance. Recent advances in hybrid surface engineering strategies integrating textures with coatings, solid lubricants, and surface hardening treatments are also reviewed. Representative applications involving bearings, cutting tools, biomedical implants, advanced ceramics, and additively manufactured materials are discussed to summarize application-oriented texture design principles. Current limitations related to thermal damage, manufacturing efficiency, coating stability, and long-term reliability are critically evaluated. Future developments are expected to focus on multifunctional surface integration, large-area manufacturing, and AI-assisted optimization for application-specific tribological interface design.