Tribological and Rheological Characterization of 3D Printed Polycarbonate: Effect of Layer Orientation, Surface Topography, and Lubrication Conditions

Understanding the tribological behavior of additively manufactured polymers is essential for their reliable use in sliding components. Tribological tests were performed on a linear reciprocating tribometer pin-on-plate configuration using a polycarbonate sample (PC–PC). To assess the influence of additive-manufacturing-induced anisotropy, three build orientations (0°, 45°, 90°) were examined. Two normal loads of 39.24 N and 58.86 N, and two sliding velocities of 15 and 20 mm/s were selected to represent typical low-load operating conditions of polymeric components. Tests were conducted in dry contact and with two commercial lubricants exhibiting distinct rheological characteristics. Surface topography was characterized before and after testing to evaluate orientation-dependent roughness evolution, while rheological measurements provided effective viscosities at shear rates corresponding to imposed velocities. Frictional behavior was analyzed through the Stribeck parameter, showing that all configurations operated within boundary or early mixed lubrication regimes. Longitudinal specimen layer orientation (90°) was expected to give the lowest friction. In fact, dominant lowest friction in most of the examination regimes gave the 45° build orientation, whereas the 0° orientation hindered lubricant entrainment and produced the highest boundary interaction. Differences in lubricant viscosity influenced Stribeck positioning and the magnitude of friction reduction, demonstrating strong coupling between layer orientation, roughness evolution, and lubrication performance.