Biofuels and Tribology: Pathways Toward Sustainable Engine  
Performance  
Vipal R. Panchal1, Someshwar S. Pandey2, Sajan K. Chourasia3*  
Mechanical Engineering Department, Gandhinagar Institute of Technology, Gandhinagar University  
382721, India  
*Corresponding Author  
Received: 30 October 2025; Accepted: 05 November 2025; Published: 09 December 2025  
ABSTRACT  
The rapid increase in automobile usage has accelerated the depletion of fossil fuels and contributed  
significantly to environmental degradation. This scenario highlights the urgent need for alternative energy  
resources that can meet growing energy demands while reducing harmful emissions from conventional fuels.  
Among the various alternatives, biofuels have emerged as a promising option for internal combustion engines.  
Numerous short-term engine tests using biofuels have shown encouraging results; however, challenges persist  
in long-term engine durability tests, which often reveal issues such as excessive carbon deposition and  
contamination of lubricating oils, ultimately leading to engine failure.  
This review aims to evaluate the tribological feasibility of biofuels in transportation applications, as their  
tribological performance plays a critical role in engine reliability and efficiency. The discussion focuses on  
various tribological aspects, including material compatibility, long-term endurance, wear behavior, and  
frictional characteristics. A detailed analysis of friction and wear parameters is presented, covering both  
compression ignition and spark ignition engines, with particular attention to the use of biodiesels, biofuels,  
and bio-oils as potential lubricants.  
Rather than introducing new experimental findings, this review consolidates and critically analyzes existing  
research, outlining past developments and highlighting future perspectives in the field of biofuel tribology.  
INTRODUCTION  
Tribology, a branch of engineering science, focuses on friction, wear, and lubrication of machine components  
in relative motion. When surfaces interact with materials and the surrounding environment, parameters such  
as wear, reliability, and maintenance requirements are affectedtogether forming the core of tribology [1]. In  
mechanical systems, the primary goal of tribology is to minimize both friction and wear through effective  
lubrication. Insufficient attention to tribological studies can lead to significant economic losses due to wasted  
materials, excess energy consumption, and reduced equipment reliability [2].  
Tribology also emphasizes selecting suitable material films for specific applications to safeguard contact  
events such as rolling, sliding, and impact interactions [3]. A lack of such optimization often results in  
shortened equipment life, increased downtime, and energy inefficiency [4]. For instance, the U.S. Department  
of Energy has reported that reducing friction and wear in engines and drivetrain components could save  
approximately $120 billion annually [5].  
The core responsibility of engine tribologists is to minimize wear and friction in sliding components through  
effective lubrication strategies. Improved tribological performance in engines leads to benefits such as better  
fuel economy, higher brake power, lower oil consumption, reduced exhaust emissions, and longer engine life  
with minimal maintenance [6]. A 10% reduction in mechanical losses has been shown to reduce fuel  
consumption by 1.5%, while nearly 48% of an engine’s energy is lost as friction in components such as  
pistons, bearings, valve trains, crankshafts, and transmissions [7].  
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Hence, adequate lubrication of all tribological engine components is crucial to achieve durability, higher  
efficiency, and lower emissions [8]. The lubricity of a fuel plays a vital role in protecting engine surfaces by  
forming films that reduce wear and friction [9]. Since 6–7% of an engine’s operating cost is attributed to  
lubricating oil consumption, the condition and compatibility of lubricants with the fuel in use must be  
carefully examined [10]. Before adopting any alternative fuel, its tribological suitability must be verified.  
Monitoring lubricating oil condition and its interaction with the fuel provides insight into engine health and  
helps assess the feasibility of biofuels in internal combustion (IC) engines [11].  
1.1 Brief Discussion on Biofuels  
The decline of fossil fuel reserves and their environmental consequences have fueled a growing global  
demand for biofuels [12]. Among the different options, biodiesel and bioethanol are widely accepted as  
alternatives for diesel and gasoline engines. Their usage has expanded rapidly in countries such as India, the  
USA, Europe, Indonesia, Japan, and Sweden [13].  
Biodiesel, a mono-alkyl ester of long-chain fatty acids, is produced from vegetable oils, animal fats, or waste  
oils through transesterification [14]. Similarly, biofuels can be derived from resources like corn, wheat,  
sugarcane, or natural gas. Production pathways include gasification, anaerobic digestion, pyrolysis, and  
hydrolysis, which yield biogas, bio-oil, and syngas. These intermediate products undergo further processes  
such as fermentation, esterification, and purification to produce biodiesel, ethanol, methanol, and other  
biofuels [1617].  
The suitability of biofuels as IC engine fuels depends on their physical and chemical properties, which must  
meet the tribological requirements of engines.  
1.2 Tribological Properties of Biofuels  
The present review focuses on the impact of biofuels on engine durability and life, highlighting their  
tribological aspects. Extensive research has been conducted worldwide on biodiesel and bioethanol owing to  
their renewability and biodegradability [18]. Biodiesel has already been commercialized as a partial diesel  
substitute in many regions [19], while ethanol is increasingly used as a gasoline replacement [20].  
Benefits of biodiesel in tribology:  
Better scuffing protection compared to petroleum diesel.  
Ester molecules in biodiesel act as surfactants on metal surfaces.  
Improved film-forming ability for surface protection.  
Oxygen content helps reduce metal-to-metal friction.  
Functional groups (CC, OH, COOH) contribute to friction reduction.  
Fatty acids (e.g., stearic acid) enhance lubrication film formation.  
Protective films reduce thermal effects during sliding contact.  
Unsaturated fatty acids further improve lubricity  
Limitations of biodiesel in tribology:  
Oxidation over long-term use causes degradation, poor lubricity, and corrosion.  
Property instability due to environmental exposure and metal interactions.  
Moisture absorption and auto-oxidation accelerate wear.  
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Low volatility contributes to oil contamination and deposits.  
Operational problems such as filter plugging, injector coking, and sticking of moving parts.  
Impurities (free fatty acids, unused catalysts, glycerides, moisture) reduce compatibility with  
automotive materials.  
Aggressive catalysts and acidic nature cause corrosion.  
Higher viscosity increases fuel injector deposits.  
Thus, lubricity plays a decisive role in evaluating the tribological performance of biofuels as alternate IC  
engine fuels.  
1.3 Necessity of Lubricity in Biofuels for IC Engine Applications  
Before biofuels are adapted for routine use, their lubricity characteristics must be evaluated through  
tribological testing. These tests examine wear, frictional behavior, corrosive potential, and effects on  
lubricating oil contamination. Since fuel passes through pumps, injectors, and other critical components,  
inherent lubricity is essential for reliable operation [21]. Tribological assessment tools include four-ball  
testers, pin-on-disc testers, high-frequency reciprocating tribometers, and wear testers, under varied loads,  
speeds, temperatures, and frequencies [22]. Biofuel performance is strongly influenced by factors such as  
corrosiveness, hygroscopicity, auto-oxidation, viscosity, and volatility. Storage conditions and metal  
interactions further affect degradation [23]. Corrosion studies, typically conducted on copper, aluminum,  
stainless steel, zinc, brass, and bronze, employ immersion tests to measure corrosion rates, surface  
morphology changes, and weight loss [2425]. Furthermore, the physical and chemical characteristics of  
biofuels influence both lubrication and wear in engine components. Tribological studies of lubricating oils are  
therefore essential to evaluate chemical interactions between biofuels and engine lubricants [2627].  
Condition monitoring of lubricating oils is widely used to assess engine performance under real operating  
conditions [2829]. Two main approaches are followed [30]:  
1. Lubricant property evaluation monitoring viscosity, density, ash content, moisture, flash point, and  
insolubles to determine lubricant life and contamination levels.  
2. Debris monitoring analyzing wear particles in oils through methods such as ferrography [3233],  
atomic absorption spectrometry, X-ray fluorescence, and ICP-OES [3435]. Microscopic examination,  
dimensional analysis, and weight measurement are also employed to quantify wear debris.  
2. Novelty and Objective of the Present Work  
The primary objective of this review is to examine the tribological behavior of biofuels under different  
operating conditions, based on a comprehensive analysis of technical literature from the past few decades.  
Special emphasis is placed on their influence on engine durability and service life.  
While biodiesel has shown promising performance in short-term engine tests, several tribological  
challengessuch as increased wear, carbon deposits, and lubricant contaminationarise during long-term  
usage. To mitigate these issues, researchers have proposed blending biodiesel with petroleum fuels in various  
proportions, thereby enhancing tribological performance in terms of friction, wear, and lubrication. Such  
improvements are typically assessed through long-term endurance tests conducted on both constant-speed and  
variable-speed IC engines under standardized operating conditions.  
In addition to being used as fuels, vegetable oils and biodiesels have also been tested as lubricating oils using  
standard tribological apparatus before application in engines. However, no comprehensive review is currently  
available in the literature that systematically addresses the use of bio-oils as lubricants in IC engines and  
evaluates their friction and wear characteristics using tribological testing methods.  
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This paper attempts to fill that gap by:  
Summarizing the latest developments in the tribological evaluation of biofuels.  
Providing insights into friction, wear, and corrosion aspects associated with their use.  
Serving as a basic guide for future research on the tribological feasibility of biofuels.  
It must be noted that this paper does not present new experimental results; instead, it consolidates findings  
from various studies on the tribological testing of biofuels and their application in IC engines.  
The paper is structured as follows:  
Methodology and test cycles for long-term endurance tests on constant-speed and variable-speed IC  
engines.  
Material compatibility studies of compression ignition (CI) engines using biofuels and biodiesels.  
3. Long-Term Endurance Test  
Endurance testing evaluates the ability of an IC engine to sustain prolonged operation under load while  
maintaining performance. Tests are conducted as per IS: 10,000 (Part VIII & IX) 1980 standards [3637].  
3.1 Constant-Speed Internal Combustion Engines  
3.1.1 Methodology  
Conducted after initial performance tests (IS: 10,000 Part VIII 1980).  
Total test duration: 32 hours, divided into two 16-hour cycles.  
After each 16-hour cycle → engine stopped for servicing/adjustments.  
Lubricating oil temperature must return to ambient conditions before restarting [38].  
3.1.2 Test Cycle (16 hours)  
Step Load Condition Duration  
Remarks  
1
2
3
4
5
6
100% load  
50% load  
4 h (incl. 0.5 h warm-up) Initial full-load run  
4 h  
Reduced load run  
110% load  
No load (idle)  
100% load  
50% load  
1 h  
Overload testing  
0.5 h  
3 h  
Engine cooling/idle  
Standard full-load run  
Final reduced load run  
3.5 h  
Cycle duration: 16 h  
Total test duration: 32 h (two cycles)  
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3.2 Variable-Speed Internal Combustion Engines  
3.2.1 Methodology  
Conducted after initial performance test + governor/speed limiter check.  
Total test duration: 100 hours, divided into 10-hour running periods.  
Between running periods → minimum 2-hour stoppage.  
Lubricating oil: manufacturer-recommended; oil temperature must return to ambient before restarting  
[39].  
3.2.2 Test Cycle (2 hours)  
Step Load Condition  
Duration Remarks  
1
2
3
4
75% full load @ max speed  
50 min  
Partial load check  
100% load @ max torque speed 45 min  
Peak torque condition  
Stabilization  
Idle condition  
5 min  
100% full load @ max speed  
20 min  
High-load verification  
Cycle duration: 2 h  
One running period: 5 cycles (10 h total)  
Total test duration: 100 h  
4. Material Compatibility of CI Engines  
Material compatibility is a critical concern whenever there is a change in the fuel composition used in  
compression ignition (CI) engines. Engine designers carefully select materials for the fuel system based on  
extensive laboratory testing methods [40]. However, the use of alternative fuels, such as biodiesel, often  
introduces challenges related to the long-term durability and reliability of engine components. Biodiesel’s  
interaction with engine materials has drawn significant attention from tribologists, as they aim to minimize  
wear, friction, and corrosion caused by fuelmaterial interactions.  
Research findings suggest that both diesel and biodiesel can lead to corrosion and wear of engine components,  
although the severity varies. Biodiesel tends to create a more corrosive environment compared to conventional  
diesel. Nonetheless, it offers superior lubricating properties, which help reduce friction and wear  
[19,20,23,24,40].  
4.1. Biodiesel in CI Engines  
Evaluating the tribological behavior of biodiesel is essential for its sustainable use in automotive applications  
[66]. Although biodiesel helps mitigate fossil fuel depletion and environmental concerns, its compatibility  
with engine materials remains a major challenge. Critical components such as the cylinder, piston, piston  
rings, and bearings are especially vulnerable when biodiesel is used.  
Tribologists therefore focus on identifying, analyzing, and overcoming the adverse effects of biodiesel on fuel  
systems and engine components. Since fuel interacts with parts like the fuel tank, fuel filter, cylinder liner,  
piston, piston rings, and connecting rod, researchers have performed endurance tests with different biodiesel  
blends to assess wear and lubrication mechanisms [67].  
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The results are categorized as follows:  
Section 4.1.1: Effects of biodiesel on engine components  
Section 4.1.2: Effects of biodiesel on corrosion behavior of engine materials  
In general, biodiesel’s higher oxygen content compared to diesel tends to accelerate wear and friction, but  
simultaneously contributes to a reduction in particulate emissions [68].  
4.1.1 Effect on Engine Components  
Wear metals commonly detected in lubricating oil samples from CI engines include iron, molybdenum,  
aluminium, copper, lead, tin, and nickel. These elements originate from two primary sources:  
1. Engine component wear cylinder head, piston, piston rings, bearings, valve seats, etc.  
2. Environmental sources fuel oil contaminants, coolant additives, and lubricant additives [72].  
The concentration of these metals in lubricating oil increases with operating time due to the accumulation of  
wear debris. Monitoring such concentrations provides a reliable indicator of engine wear. Once the  
concentration of any element exceeds its warning limit, severe wear is likely occurring in the engine. Table  
lists the warning levels of common wear metals in diesel engines [55].  
Table . Warning levels of trace metals in diesel engines  
Element  
Warning level (ppm)  
Iron (Fe)  
100  
Aluminium (Al) 25  
Copper (Cu)  
Lead (Pb)  
Tin (Sn)  
50  
50  
20  
Chromium (Cr) 20  
Silicon (Si)  
Boron (B)  
25  
25  
Studies have shown that biodiesel can reduce wear in several key engine components due to its inherent  
lubricity-enhancing properties. For instance:  
Piston top deposits and injector coking were reduced, and ash content in lubricating oil was lower in  
biodiesel-fueled engines compared to diesel [55].  
Durability tests revealed improved piston ring wear resistance with higher biodiesel concentrations  
compared to diesel [57].  
Lower wear was reported in components such as pistons, valves, piston rings, and liners, whereas  
higher wear was observed in main bearings and crank pins with biodiesel use [49].  
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Structural changes were observed in injection system components, such as injector nozzles and pump  
pistons, when neat biodiesel was used [48].  
Overall, increasing biodiesel concentration in blends reduces friction and wear, attributed to the presence of  
free fatty acids, oxygenated moieties, and unsaturated molecules [73]. Worn surface distortion also decreases  
with higher biodiesel content. However, increased rotational speeds can reduce lubricity, leading to higher  
friction and wear [74].  
Biodiesel’s lubricity, though beneficial, is influenced by several factors:  
Enhancing lubricity: free fatty acids, unsaturated compounds, glycerides, long-chain molecules, and  
high viscosity [8082].  
Reducing lubricity: oxidation, moisture absorption, auto-oxidation, and corrosiveness [83].  
While biodiesel blends enhance lubricity compared to ultra-low-sulfur diesel, their high viscosity may impair  
fuel atomization and injector performance [83]. Studies also indicated that oxidation products in biodiesel can  
interact with anti-wear additives such as ZDDP, reducing overall lubricant effectiveness [8586]. Glycerin  
and water contamination in lubricating oil further influence wear behavior [87]. Moreover, biodiesel-fueled  
engines showed greater oxidative degradation and polymerization of lubricating oil compared to diesel  
engines [88].  
4.1.2 Effect of Corrosion on Engine Components  
The oxidation of biodiesel results in the formation of mono-carboxylic acids, which significantly increase  
corrosion risk [89]. At elevated temperatures, biodiesel oxidizes more rapidly, producing water and other by-  
products that accelerate tribo-corrosiona combined effect of wear and corrosion [9091].  
Although biodiesel generally provides better lubricity than diesel, its higher oxidation tendency contributes to  
material degradation. Methyl esters react with atmospheric oxygen to form ketones, aldehydes, and carboxylic  
acids [93]. The presence of metals such as copper catalyzes oxidation, further accelerating degradation, as  
confirmed by FTIR spectroscopy [94]. Other metal impurities and unsaturated fatty acids also reduce the  
oxidation stability of biodiesel [9596].  
Biodegradation studies indicate that biodiesel degrades between 7789% within 28 days, compared to only  
~18% for diesel, due to enzyme-catalyzed oxidation [97]. While this biodegradability offers environmental  
advantages, it also impacts long-term fuel stability and tribological performance [98].  
Research findings include:  
Higher biodiesel blends experience increased wear due to acidic constituents formed during  
combustion [99].  
Copper alloys corrode more severely in biodiesel compared to ferrous alloys [100101].  
Prolonged exposure to biodiesel not only corrodes engine metals but also degrades fuel properties due  
to unsaturated molecules and compositional effects [102105].  
Thus, the dual nature of biodieselproviding enhanced lubricity yet promoting tribo-corrosionpresents a  
major challenge in ensuring material compatibility of CI engines.  
CONCLUSIONS  
This review has examined the tribological implications of biofuels with specific attention to wear behavior,  
lubrication mechanisms, frictional response, corrosion effects, and long-term endurance testing in IC engines.  
A comprehensive assessment of existing studies indicates that:  
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Biodiesel generally enhances lubricity due to its polar ester groups and oxygenated molecular structure.  
However, long-term durability concerns persist, including oxidative instability, lubricating oil  
degradation, and corrosive wear, especially on copper-containing alloys.  
Condition monitoring techniques such as ferrography, spectrometric analysis, and wear debris  
evaluation remain effective diagnostic tools for detecting early-stage engine wear.  
Material compatibility challenges continue to limit widespread implementation, particularly due to  
biodiesel’s hygroscopic nature, auto-oxidation, and the formation of acidic by-products.  
Overall, while biodiesel demonstrates promising tribological performance in controlled short-term tests,  
achieving reliable long-term engine operation requires deeper understanding of corrosion mechanisms,  
material interactions, and fuellubricant chemistry.  
Future Scope  
Based on current research gaps and reviewer recommendations, future studies should focus on:  
Experimental validation under real engine conditions to verify summarized tribological findings and  
support practical implementation.  
Integration of modern analytical techniques, such as 3D surface topography, wear debris morphology  
analysis, and advanced lubrication modeling, to better understand wear mechanisms.  
Development of hybrid bio-lubricant formulations and nano-additive packages to improve anti-wear,  
anti-friction, and anti-corrosion characteristics of both fuels and lubricating oils.  
Assessment of long-term economic and environmental trade-offs, including life-cycle analyses for  
various biofuel blends.  
Comparative case studies on long-duration endurance tests using blended and pure biofuels to evaluate  
durability, component degradation, and lubricant condition over extended operation.  
These future research directions will strengthen the scientific understanding of biofuel tribology and support  
the transition toward cleaner, more sustainable engine technologies.  
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