Exceptional performance of bi-directionally reinforced composite of PEEK manufactured by commingling technique using poly(p-phenylene-benzobisoxazole) (PBO) fibers

Abstract

The present study explored the braiding/commingling technique to develop a composite of PEEK and poly(p-phenylene-benzobisoxazole)(PBO) fibers (Zylon) in equal amounts followed by compression molding. The braided yarns of PEEK and Zylon were used to develop the plain weave fabric. Physical, thermal, and mechanical properties (tensile, impact, and flexural mode) of the developed composites were investigated and compared with unreinforced PEEK. An in-depth analysis of the microstructure was done using X-ray micro-tomography. The tribological performance of the developed composites was studied in adhesive, abrasive, and erosive wear modes. The transfer film analysis was done extensively by Raman spectroscopy and scanning electron microscopy (SEM). A detailed analysis of the fibers on worn surfaces was done by atomic force microscopy (AFM). The developed composite exhibited super- performance in terms of % improvement compared to PEEK (6900% in impact strength, ≈ 700% in flexural modulus, ≈ 200% in tensile modulus, ≈ 160% in tensile strength, 53% in flexural strength, and 43% hardness apart from wear resistance (≈90% in adhesive, 12% in abrasive, and 68% in erosive). The composite can be exploited for structural and tribological applications.