Coating-induced lubrication in granular media: from particle-scale tribology to bulk rheology

Abstract

Coated granular materials are involved in numerous industrial processes, including powder handling in pharmaceuticals, additive manufacturing, cement production, and food processing, where surface treatments control flowability, prevent agglomeration, and improve product consistency. Despite their widespread use, the influence of coatings on the collective behavior of granular materials remains poorly understood. While dry granular flows are well described by the μ(I) rheology for frictional, noncohesive particles, many real-world systems involve additional interparticle interactions that fall outside this framework. Here, we investigate how polymer coatings on silica grains modify dry granular rheology by introducing non-Coulombic frictional behavior at the particle scale. Pressure-imposed rheological experiments reveal that coatings activate a low-friction regime in which the bulk friction coefficient and packing fraction approach values typical of frictionless grains. The transition from this lubricated state to a conventional frictional regime depends on both normal stress and shear rate, indicating stress- and velocity-dependent contact mechanics. Tribological measurements show that interparticle friction decreases with coating thickness and sliding velocity, but increases with normal load. Building on these findings, we develop a mean-field rheological model that extends the classical μ(I) framework to include coating-dependent, non-Coulombic friction. Discrete Element Method simulations incorporating the measured friction law capture the key qualitative features observed experimentally. These results demonstrate that controlled surface coatings provide a powerful route to engineer granular rheology and enhance flowability across various industrial applications.