Design/methodology/approach A PTFE layer was sintered on the surface of a steel disk, and a lubricant with additives was applied to the surface of the steel disk. A friction and wear tester was used to evaluate the tribological properties and insulation capacity. Fourier transform infrared spectrometer was used to analyze the changes in the composition of the lubricant, and X-ray photoelectron spectroscopy was used to analyze the chemical composition of the worn surface. Findings It was found that incorporating the PTFE film with PSAIL 2280 significantly enhanced both the friction reduction and insulation capabilities at the electrical contact interface during sliding. The system consistently achieved ultra-low friction coefficients (COF < 0.01) under loads of 2–4 N and elucidated the underlying lubrication mechanisms. Originality/value This work not only confirm the potential of PTFE films in insulating electrical contact lubrication but also offer a viable approach for maintaining efficient and stable low-friction wear conditions. Peer review The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-06-2024-0222/