Wear Of Composites Research Articles

Wear Resistance of B4C-TiB2 Ceramic Composite

The effects of microstructure and mechanical properties on the wear resistance of B4C-TiB2 ceramic composite were studied. The composite was hot pressed from a B4C-TiO2 precursor at a temperature range of 1800 and 1850 °C. Both the relative density and amount of TiB2 secondary phase of the B4C-TiB2 composite increased with the amount of TiO2 sintering additive in B4C-TiO2 precursor. The hardness of the composite increased with a secondary phase portion up to 29.8 vol.% TiB2. However, the positive effect of TiB2 secondary phase on the fracture toughness of B4C-TiB2 composite was measured in the complete experimental range, with the highest average attained value of 7.51 MPa·m1/2. The wear resistance of B4C-TiB2 composite increased with both the hardness and fracture toughness. The best wear resistance was achieved with the composite with a higher hardness value of 29.74 GPa. This sample consisted of 29.8 vol.% TiB2 secondary phase and reached a fracture toughness value of 6.91 MPa·m1/2. The fracture-induced mechanical wear of B4C-TiB2 composite was the main wear mechanism during the pin-on-disc wear test. Transgranular fracture with pullout of the surface and micro-crack formation in the direction perpendicular to the wear direction was observed on the worn surfaces.

A micromechanical approach to the wear of fiber-reinforced composites

A micromechanical approach to the wear of fiber-reinforced composites

Effects of WC Particles on the Microstructure and Properties of Copper Matrix Composites by Selective Laser Melting

Selective Laser Melting (SLM), as an emerging additive manufacturing technology, has attracted increasing attention in the field of copper alloys. To reduce the production cost of SLM-formed copper alloys and enhance the mechanical properties of the alloy materials, this work uses CuSn10 alloy powder prepared by the water atomization method as the raw material, and optimizes the process parameters during SLM through the response surface and variance analysis methods, to prepare almost fully dense CuSn10 alloy blocks. By adding a certain proportion of WC hard particles to the CuSn10 alloy powder, this work investigates the microstructural evolution and mechanical properties of the specimens before and after the addition of particles, and explores the regularity of the influence of the addition of hard particles on the microstructural evolution and mechanical properties of the formed parts by comparing the experimental results. The results show that the SLM-formed CuSn10 specimens exhibit a fine-grained microstructure composed of cellular and dendritic structures. The addition of WC hard particles changes the microstructure of the composite material, eliminating the preferred growth inside the specimens, and due to the effects of hard carbide phase, heterogeneous nucleation and dispersion strengthening, a more refined and uniform microstructure is achieved. The performance of the specimens also varies considerably, with the Vickers hardness increasing from 155HV to 215HV, the ultimate tensile strength increasing from 578MPa to 625MPa, and the elongation at fracture decreasing from 15% to 5%. The wear resistance and corrosion resistance show the same trend, with the wear resistance and corrosion resistance of the composite material first decreasing and then increasing as the WC content increases, reaching the best when the content is 10%. It can be seen that by reasonably adjusting the proportion of the WC reinforcement phase in the copper-based composite material, the hardness and wear resistance of the SLM-formed CuSn10 alloy can be significantly improved, expanding the engineering application prospects of copper alloy parts in extreme working conditions such as wear and corrosion.

Tribological Performance of Short Fibers Reinforced Thermoplastic Polyurethane Composite Materials Under Water-Lubricated Condition.

The water-lubricated bearing plays a crucial role in the ship propulsion system, significantly impacting vessel safety. However, under the harsh working conditions of low-speed and heavy-load, the lubrication state of water-lubricated bearings is usually poor, leading to serious friction and wear. To improve the tribological performance of composites and reduce friction, three short fibers (ultra-high-molecular-weight polyethylene fibers, basalt fibers, and bamboo fibers) with the same mass fraction (5%) were added into the melted thermoplastic polyurethane (TPU). The tribological behavior of these three composites under different loads and rotation speeds was investigated using the CBZ-1 friction and wear tester. Through the comprehensive analysis of the friction coefficient, the wear mass loss, and the surface morphology, it was confirmed that the filled fiber positively affected the tribological performance of thermoplastic polyurethane materials. The experimental results indicated that basalt fiber significantly improved the tribological performance of TPU, and the friction coefficient of the sample was only 0.088 under the working conditions of 0.5 MPa and 250 r/min, which was 70.57% lower than that of pure TPU material. And in all the tests, the minimum wear of the basalt fiber-reinforced composite is only 0.4 mg, which is also the smallest of all the materials under all conditions, and a decrease of 98.69% compared to TPU. Under high loads, ultra-high-molecular-weight polyethylene fiber and bamboo fiber-reinforced composites have smoother surfaces and exhibit better tribological properties. This study provides an experimental foundation for tribological performance enhancement for environmentally friendly, water-lubricated bearing composites.

Experimental investigation of hardness, friction, and wear in jute fiber-based hybrid polymer composites reinforced with SS304 and aluminium

Experimental investigation of hardness, friction, and wear in jute fiber-based hybrid polymer composites reinforced with SS304 and aluminium

Comparative Study on Micro and Nano Sized SiC Particulates Reinforced Al7075 Composites using Stir Casting Process

This paper is designed to investigate the wear and mechanical characterization of metal matrix composites (MMCs) by using micro and nano SiC on Al to study the influence of micro/nano SiC on the properties of fabiricated composite. Micro and nano-composites with 1-4% of SiCp were developed using stircasting processes. From the outcomes, an improved grain refinement of micro and nano-composites when compared to monolithic was seen from the microstructural study. It found that an increase in SiC particulates content caused enhanced mechanical properties. Though, nano SiC reinforced MMCs resulted in improved mechanical properties compared to micro sized SiC particulates reinforced MMCs. The wear study was evaluated for comparison of micro/nano MMCs. The investigation indicates that, wear resistance of nano composites is better as compared to micro-SiCp reinforced MMCs. Fractured surfaces were inspected by the SEM analysis to study the nature of fracture in the micro and nano composite samples.

Synergistic Enhancement of the High-Temperature Friction and Wear Behavior of PTFE Matrix Composites with the Addition of CF, PEEK, and TiC.

With the rapid development of the aerospace, automobile, and ocean industries, there is an urgent need for the fabrication of high-performance polymer matrix composites with low friction and wear in wide temperature ranges. In this paper, polytetrafluoroethylenes (PTFEs) doped with polyether-ether-ketone (PEEK), carbon fiber (CF), and TiC were prepared, and the effects of testing temperatures from room temperature to 250 °C in air conditions were investigated. The results showed that the friction coefficient of the PTFE matrix composites had no obviously changing trend, while the wear resistance properties were significantly improved. Due to the synergistic lubrication and enhancement of CF, PEEK, and TiC, the wear rate for composites with these particles decreased from (2.04-2.72) × 10-3 mm3/Nm for pure PTFE to (0.67-1.96) × 10-4 mm3/Nm. Moreover, the SEM analysis results showed that the main wear mechanisms are fatigue and abrasive wear for the PTFE matrix composites. The results obtained in this study will provide data and technical support for the development of high-performance polymer matrix composites with low friction and wear that can be used over a wide temperature range.

Enhancing microstructure, nanomechanical and anti-wear characteristics of spark plasma sintered Ti6Al4V alloy via nickel-silicon carbide addition

This study examines the nanomechanical and anti-wear behaviour of spark plasma sintered Ti6Al4V matrix composites reinforced with Ni and SiC particles. Microstructural analysis revealed the in-situ formation of the hard TiC, Ti3SiC2 and Ti5Si3 phases within the metal matrix. Nanoindentation analysis revealed that the composite containing 10 wt% SiC (TNi10SiC) exhibited significantly higher nanohardness (about 10.3 GPa) and elastic modulus (∼ 177.7 GPa) than the unreinforced Ti6Al4V alloy (sample T). The improved nanomechanical performance of the composites was attributed to the load-carrying capacity of the hard, in-situ formed reinforcement phases. The anti-wear characteristics of the composites showed that TNi5SiC composite displayed superior wear resistance with a specific wear rate of 4.75 ± 0.34 x 10-4 mm3/Nm and 2.15 ± 0.34 x 10-4 mm3/Nm under an applied loads of 10 N and 20 N, respectively, among the sintered samples. This represents about 67% and 29% reduction in specific wear rate relative to sample T. This enhanced tribological behaviour was ascribed to the increased surface hardness, the formation of a stable transfer layer, and the reduction in direct asperity contact at the sliding interfaces. However, reinforcement pull-out aggravates abrasive wear and leads to a higher specific wear rate for TNi10SiC composite. This work provides valuable information for advancing Ti6Al4V-based composites for enhanced structural and wear-resistant applications.

Optimization of Abrasive Wear Parameters and Thermo-Mechanical Properties of Bauhinia Vahlii and Grewia Optiva Fiber Reinforced Hybrid Polymer Composites

Natural fiber-reinforced polymer composite offers competitive solutions for lightweight applications but faces significant abrasive wear challenges in many industrial and automobile applications. The current study aims to conduct mechanical, physical, and dynamic mechanical analyses, as well as three body abrasion examinations, on grewia-optiva (GO) and bauhinia-vahlii (BV) natural fiber-reinforced epoxy-based hybrid polymer composites containing marble dust as filler. Initially, the woven mat was knitted with an equal amount of grewia-optiva and bauhinia-vahlii natural fibers. Three weight percentages of the woven mat i.e. 10, 20, and 30wt.% were used as reinforcement, and industrial waste marble dust with a fixed amount of 5wt.% was also used as a filler material. GO, and BV fiber mats were chemically treated with 10wt—% NaOH for the cleaning and surface modification of fibers before their use as reinforcement. The fabricated composites' physical and mechanical characteristics, i.e., density, water absorption, hardness, impact, flexural, and tensile strength were examined experimentally. The value of the damping factor (tan δ), storage modulus (Eʹ), and loss modulus (Eʹʹ) of the developed composites were analyzed by a dynamic mechanical analyzer (DMA). The fabricated composites' three-body abrasive wear characteristics were also examined with varying parameters i.e. A: fiber loading, B: sliding distance, and C: normal load. The results show that increasing the fiber loading and using a constant amount of discarded marble dust improves all mechanical characteristics. The tensile strength, flexural strength, impact strength, and hardness improves by 15.99%, 26.30%, 24.40%, and 30.39% respectively for 10wt.% to 30wt.% fiber loading. The composites exhibit significant improvements in damping properties with fiber loading. Moreover, parameters i.e. normal load, speed, and fiber loading have contributed to abrasive wear of composites at 29.70%, 24.81%, and 19.07% respectively. This study will aid in the analysis of the morphological, mechanical, and thermo-mechanical properties of a new class of composite material that might be used for producing natural polymeric roofing systems, boats, and floors, as well as for the automobile industry.

Spark Plasma Sintering Preparation of Tungsten Carbide-Reinforced Iron-Based Composite Materials: Wear Resistance Performance and Mechanism.

The spark plasma sintering (SPS) process was used to create iron-based composites reinforced with tungsten carbide (WC) particles of various morphologies, and the effect of WC particle morphology on material wear resistance was systematically investigated. The experiment revealed that the addition of non-spherical WC (CTC-A) significantly altered the composites' friction coefficient, wear morphology, and wear mechanism. As the CTC-A content increased, the composites' wear rate decreased at first, then increased, and then decreased again. Composites with a CTC-A concentration of 10% had a minimum wear rate of 2.7 × 10-6 mm3/(N·m) and peaked at 20%. SEM analysis indicated that the wear mechanism gradually changed from initial oxidative wear to abrasive wear as the CTC-A content increased, and the wear morphology transitioned from smooth to rough with the appearance of numerous abrasives and cracks. The study demonstrated that the low content of non-spherical WC particles during sintering significantly increased the hardness of the matrix by forming carbide phases, while a high content led to increased surface roughness, inducing abrasive wear and reducing wear performance. These findings provide a significant theoretical basis and practical guidance for optimizing the design of iron-based composites.

Mechanical, wear, fatigue, water absorption and flammability of silane-treated Indian squid chitin powder-dispersed pineapple fiber-polyester composite

Mechanical, wear, fatigue, water absorption and flammability of silane-treated Indian squid chitin powder-dispersed pineapple fiber-polyester composite

One stone three birds: Multifunctional epoxy composites based on rice-granular nickel/iron bimetallic phyllosilicates enable excellent compression, anti-wear and lubricating properties under wet-sliding conditions

Epoxy resin (EP) is a versatile thermoset resin extensively employed as protective coatings. However, its brittleness causes poor wear resistance and presents a significant challenge in the application under harsh environmental circumstances. The preparation of EP composites by rationally selecting functional inorganic fillers offers a promising strategy for enhancing mechanical and tribological properties. In this paper, multifunctional EP composites were successfully fabricated with varying mass fractions of rice-granular nickel/iron bimetallic phyllosilicate (NiFePS). The compressive properties, water contact angles, wet-sliding responses, and the morphological analysis of worn surfaces for EP composites were carried out and discussed in detail. Results indicate that the incorporated NiFePS scarcely alters the compressive stress-strain curves, still exhibiting the representative stages including elastic transformation, stress yielding and strain hardening throughout the entire compressive process. The compressive strength, elastic modulus and fracture energy initially increase and then decrease, attaining the maximum values of 266.3 MPa, 4.43 GPa, and 72.1 J/cm², respectively, with the addition of merely 1 % NiFePS. Furthermore, the introduction of NiFePS significantly reduces the water contact angle, transforming the surface of EP composite from hydrophobic to hydrophilic. The friction coefficient and wear rate of EP composites decrease sharply with the addition of NiFePS, achieving the lowest values of 0.136 and 1.24×10⁻⁶ mm³/Nm simultaneously at a filler concentration of 1 %, which represent reductions of 17.07 % and 70.55 %, respectively, compared to the resin matrix. Additionally, the wet-sliding responses affected by various applied loads, rotating speeds and abrasive durations are comprehensively discussed. Finally, the wear mechanism of EP composites is elucidated through in-depth examinations of the evolving morphologies and chemical compositions of the worn surfaces. This work presents a feasible three-in-one technology for developing multifunctional materials with significant potential in high-performance composites and coatings.

Ultra-low Friction and Wear of Phenolic Composites Reinforced with Halloysite Nanotubes

To decrease the number of interfaces and facilitate the designing of polymer tribo-composites, traditional fillers in phenol-formaldehyde resins (PF) with multiple dimensions and components were replaced with halloysite nanotubes (HNTs). The composites’ tribological performance were studied under a wide range of pv (pressure × speed) conditions. It is revealed that the single incorporation of HNTs significantly lower the friction and wear of PF. In particular, the composites exhibit ultra-low friction and wear under high pv conditions. Mechanism analyses demonstrate that the composites’ tribofilms show distinctly different nanostructures depending on the pv conditions, which was studied thoroughly through morphological and chemical characterizations. Findings of the present work provide new strategies for formulating tribo-composites for applications subjected to harsh sliding conditions.

Development and Characterization of Al-SiC Metal Matrix Composites Through Microwave Processing and Extrusion

Metal matrix composites (MMCs) have garnered significant attention due to their exceptionally lightweight nature, adaptability for a wide range of applications, and exceptional mechanical properties. This investigation delves into the tribological characteristics of aluminum-silicon carbide (Al-SiC) microelectrodes. These MMCs were refined through extrusion after being fabricated using a novel microwave-assisted powder metallurgy process. The impact of reinforcement content on the material's mechanical strength and wear resistance was assessed by varying the weight percentages of SiC (10%, 15%, and 20%). The results indicate that the uniform distribution of SiC within the aluminum matrix significantly enhances the composite's hardness and wear resistance. The addition of 20% SiC resulted in a 28% reduction in the wear rate compared to pure aluminum. In addition, the extrusion procedure improved these properties by aligning the SiC particulates in the direction of extrusion and reducing porosity. This investigation demonstrates that the combination of microwave sintering and extrusion can produce high-performance Al-SiC MMCs with enhanced abrasion resistance and mechanical properties, making them suitable for industrial applications that require lightweight materials and durability.

Improving the morphology of terrace-like transfer film to reduce wear rate of graphite/PTFE composites via filling low content silica

PurposeThe purpose of this paper is to fill low content of silica to improve the wear resistance of graphite/polytetrafluoroethylene (PTFE) composites, and to discuss the effect of low content of silica on the morphology of terrace-like transfer film.Design/methodology/approachThe tribological properties of silica/graphite/PTFE composites were tested by rotating pin-on-disk friction and wear tester, and the morphology of terrace-like transfer film was observed by 3D laser scanning microscope and quantitatively analyzed through the multi-Gaussian function linear combination model.FindingsThe results showed that adding 3 wt.% silica in graphite/PTFE composites can reduce the wear rate by 87%. More importantly, the morphology of terrace-like transfer film changed significantly after filling a small amount of silica, including the increase of the number of layers and the coverage rate of transfer film.Originality/valueThis work is of great significance for further understanding the transfer film and achieving its morphology control to optimize the wear of high performance PTFE composites.

Tribological properties of polyimide coating filled with solvent-free covalent carbon quantum dots nanofluids

Novel organic coatings were developed by incorporating solvent-free covalent carbon quantum dots nanofluids (CQDs NFs) into a polyimide (PI) matrix. The tribological properties of CQDs NFs/PI composite coatings were tested using a ball-on-disk tribometer, revealing that even a low loading of CQDs NFs significantly improved tribological performance of PI. Molecular dynamics (MD) simulations and nanoindentation tests showed that CQDs NFs restricted PI molecular chain movement, enhancing mechanical properties. Additionally, CQDs NFs promoted the formation of stable transfer films on steel surfaces, improving wear resistance. This study confirms CQDs NFs' effectiveness in modifying PI composite coatings' friction and wear properties.

Dry sliding wear behaviour of AA6082/BN/Mos2 hybrid metal matrix composites synthesized using stir casting process

This study examines the wear behaviour of AA6082/x Boron Nitride (BN) (x = 1, 2, 3 wt.%)/1 wt.% of Molybdenum Disulphide (MoS2), a novel hybrid metal matrix composite (MMC), under dry sliding conditions. The composite was fabricated through liquid-state processing, i.e., stir casting. A pin-on-disk tribometer was used to estimate the coefficient of friction (COF) and wear rate by varying tribological process parameters under dry sliding conditions. The results show that at the maximum load of 40 N, the wear rate of the unreinforced alloy is observed 4.077 × 10−2 mm3/m, while at the AA6082/3 wt. of %, BN/1 wt. % of the MoS2 composite's wear rate is reduced to 2.162 × 10−2 mm3/m. Further, the wear rate increases as the sliding distance increases from 500 m to 2000 m. Moreover, the friction coefficient of the unreinforced alloy is observed 0.37, whereas the AA6082/3 wt.% of BN/1 wt.% of MoS2 composites is observed 0.31 under reduced loads. It might be due to the presence of hard ceramic BN and MoS2 reinforcements enhancing the developed composite's resistance to wear by forming a mechanically mixed layer (Fe2O3) on the sliding contact surface. Moreover, the novel hybrid composite materials exhibit a lower coefficient of friction at higher sliding velocities, sliding distances, and applied loads. However, minimal fine grooves with limited abrasion are observed on the worn surface, which was examined through a scanning electron microscope.

Advanced Machine Learning and Experimental Studies of Polypropylene Based Polyesters Tribological Composite Systems for Sustainable Recycling Automation and Digitalization

Digitalization and automation are emerging solutions to the complex problems of recycling. In this research work, the experimental and Python based Archard deep learning wear rate models are introduced regarding recycling automation and composite tribological systems optimization. The optimum polyester fibers (PESF) of length of 3-3.5 mm were used for fabrication of polypropylene (PP)-PESF composite systems. The deformation, high texture, asperities, and micro-cracks were observed during scanning electron microscope and machine-learning studies. The lowest experimental value of abrasive wear of 3.0 × 10-6 mm3/Nm was observed for PP. Comparatively, higher experimental values of abrasive wear of the PP-PESF composites are found in the range of 4.35 × 10-6 to 4.7 × 10-6 mm3/Nm due to presence micro-defects on the surface of composites. The experimental values of Coefficient of friction (COF) of PP and PP-PESF are found in the range of 0.70 - 0.8 and 1.1 - 1.3, respectively. The experimental values of abrasive wear and COF are found compatible with literature. Similarly, the simulated values of abrasive wear of PP and PP-PESF composites are predicted in the range of 4.8×10-7 to 3.75×10-7 mm3/Nm, respectively. The predicted values of PP and PP-PESF composite show better resistance towards abrasive wear. The proposed experimental and simulated (in terms of Python coding, machine learning, image processing, artificial intelligence, and deep learning studies) research work can be introduced industrially for automation as well as digitalization of grinding of PES waste, processing, tribological testing, and SEM characterization evaluations.

Dry Friction and Wear of Graphite-Filled PTFE Composites using Taguchi Approach

Dry Friction and Wear of Graphite-Filled PTFE Composites using Taguchi Approach

Copper-Nickel/SiC composites for applications on contact electrodes

Novel copper-nickel matrix composites reinforced with silicon carbide (SiC) micro particles for metal contact applications were manufactured by powder metallurgy technology and were experimentally characterized. Cu and Cu alloys are commonly used as metal contact for either vacuum, oil, or SF6 in low-voltage circuit breaker devices, but their application in environments with the presence of oxygen is limited due to their tendency to form high-resistance copper oxides. Thus, the addition of Ni as an alloying element provides resistance to both humidity and several corrosive environments and increases the composites' hardness, mechanical strength, and wear resistance. Moreover, SiC was chosen due to its contribution to mechanical strength, mouldability, low production cost, and non-reactive nature at ordinary temperatures. Here, three SiC particle size distributions were considered, and it was found that the composites' physical properties are also dependent on the ceramic loading. After evaluating these properties, two specific SiC concentrations were potentially considered for electrode applications: 10 wt% and 20 wt%. The obtained hardness values are in the range of 55–65 HR30T which guarantees the necessary strength without detriment of the contact area whereas the welding is minimized. In addition to a homogeneous particle distribution in the solid material, specific wear resistance of ∼10−5 mm3N−1m−1 and electrical conductivities of ∼20 %IACS were obtained. Considering these parameters, Cu-Ni/SiC composites' performance is not compromised compared to commercial Ag/WC materials commonly used in metal contact applications.