High interface friction is a primary cause for adhesive pickup in cold forging and extrusion of aluminum alloys and of wear of sliding surfaces in thrust bearings and seals. This paper describes investigations of femtosecond laser texturing for reduction of interface friction on sliding surfaces. Direct-write femtosecond pulsed laser micromachining is used to create microgroove patterns with varying size and density on metal forming dies. Ablation of patterned textures using a Digital Light Processor (DLP) programmable mask and a homogenized femtosecond laser beam is also studied. The achievable resolution and depth profiles and material removal rate for laser micromachining of lubrication-enhancing features is characterized. In metal forming tests, the effectiveness of various laser-machined patterns for enhancing interface lubrication is determined.
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