The Effects of Copper and Polytetrafluoroethylene (PTFE) on Thermal Conductivity and Tribological Behavior of Polyoxymethylene (POM) Composites

The effects of copper and polytetrafluoroethylene (PTFE) on thermal conductivity and tribological behavior of polyoxymethylene (POM) composites were investigated by a hot disk thermal analyzer and an M-2000 friction and abrasion testing machine. The results indicated that the incorporation of 3 wt% copper particles into POM had little effect on the thermal conductivity of POM composites, but led to the decreased friction coefficient and wear rate of composites. As the copper content was increased, the thermal conductivity increased and reached 0.477 W m^?1 K^?1 for POM-25% Cu composite, an increase of 35.9% compared with that of unfilled POM, while the friction coefficient and wear rate of composites also increased. The incorporation of PTFE into POM-Cu composites had a negligible effect on the thermal conductivity of composites, but helped in the formation of a continuous and uniform transfer film and resulted in the reduction in the friction coefficient and wear rate of composites. The POM-15% Cu-10% PTFE composite, with a value of wear rate similar to unfilled POM possessed higher thermal conductivity and lower friction coefficient.     

Synthesis and tribological properties of AA5052-base insitu composites

Abstract

It is important to optimize the properties of a material for a particular application, hence, to find the suitable material for tribological applications, the wear and friction behaviour of AA5052 in situ composites with different kind of reinforcements have been investigated. For present study, three in situ formed composites have been produced with different reinforcements namely Al₃Zr, ZrB₂ and combination of both (Al₃Zr + ZrB₂) by direct melt reaction (DMR) technique. The as-cast composites and base alloy have been characterized by X-ray diffraction (XRD), optical microscopy, electron microscopy, tensile testing, hardness and dry sliding wear and friction tests. XRD results indicate the successful formation of second phase reinforcement particles in all composites. Wear test results indicate that the cumulative volume loss increases with an increase in sliding distance while coefficient of friction shows a fluctuating tendency, whereas with increasing applied load, wear rate shows an increasing trend while coefficient of friction shows decreasing trend. The variation of wear rate with composites indicates that the composite with multiple reinforcement (Al₃Zr + ZrB₂) has lowest wear rate among all as-cast composites and base alloy, while coefficient of friction is higher. The responsible mechanisms concerned with wear and friction results have been discussed in detail with the help of the observation on worn surface analysis by scanning electron microscope (SEM) and 3D-profilometer. All tribological results have been correlated with the microstructural properties, strength parameters and bulk hardness of the composites.     

Effects of carbon fiber surface treatment on the tribological properties of 2D woven carbon fabric/polyimide composites

Polyacrylonitrile (PAN)-based carbon fabric (CF) was modified with strong HNO₃ oxidation and then introduced into polyimide (PI) composites. The friction and wear properties of the carbon fabric reinforced polyimide composites (CFRP), sliding against GCr15 stainless steel rings, were investigated on an M-2000 model ring-on-block test rig under dry sliding. Experimental results revealed that the carbon fiber surface treatment largely reduced the friction and wear of the CFRP. Compared with the untreated ones, the surface-modified CF can enhance the tribological properties of CFRP efficiently due to the improved adhesion between the CF and the PI matrix. Scanning electron microscope (SEM) and X-ray photoelectron spectroscopy (XPS) study of the carbon fiber surface showed that the fiber surface became rougher and the oxygen concentration increased greatly after surface treatment, which improved the adhesion between the fiber and the PI matrix and improved the friction-reduction and anti-wear properties of the CFRP. An erratum to this article can be found at     

Structural and Tribological Properties of Polytetrafluoroethylene Composites Filled with Glass Fiber and Al2O3 in Atomic Oxygen Environment

Effects of atomic oxygen (AO) irradiation on the structural and tribological behaviors of polytetrafluoroethylene (PTFE) composites filled with both glass fibers and Al₂O₃ were investigated in a ground-based simulation facility, in which the average energy of AO was about 5 eV and the flux was 5.0 × 10¹⁵/cm² s. It was found that AO irradiation first induced the degradation of PTFE molecular chains on the sample surface, and then resulted in a change of surface morphology. The addition of Al₂O₃ filler significantly increased the AO resistance property of PTFE composites. Friction and wear tests indicated that AO irradiation affected the wear rate and increased the friction coefficient of specimens. The PTFE composite containing 10% Al₂O₃ exhibit the best AO resistance and lower wear rate after long time AO irradiation.     

Preparation and characterization of nickel nano-Al2O3 composite coatings by sediment co-deposition

Ni-Al₂O₃ composite coatings were prepared by using sediment co-deposition (SCD) technique and conventional electroplating (CEP) technique from Watt's type electrolyte without any additives. The microstructure, hardness, and wear resistance of resulting composites were investigated. The results show that the incorporation of nano-Al₂O₃ particles changes the surface morphology of nickel matrix. The preferential orientation is modified from (2 0 0) plane to (1 1 1) plane. The microhardness of Ni-Al₂O₃ composite coatings in the SCD technique are higher than that of the CEP technique and pure Ni coating and increase with the increasing of the nano-Al₂O₃ particles concentration in plating solution. The wear rate of the Ni-Al₂O₃ composite coating fabricated via SCD technique with 10 g/l nano-Al₂O₃ particles in plating bath is approximately one order of magnitude lower than that of pure Ni coating. Wear resistance for SCD obtained composite coatings is superior to that obtained by the CEP technique. The wear mechanism of pure Ni and nickel nano-Al₂O₃ composite coatings are adhesive wear and abrasive wear, respectively.     

Studies on wettability, mechanical and tribological properties of the polyurethane composites filled with talc

A series of polyurethane (PU)/talc composites modified by a high molecular weight hydroxyl-terminated polydimethylsiloxane (HTPDMS) were prepared. The effect of the talc content on the mechanical, wettability and tribological properties of the PU composites was studied. Tensile strength of the PU composites reached to the maximum after adding 5% talc. The water contact angles (CA) of the original surfaces and worn surfaces of the polyurethane composites were measured. The experimental results indicated that the contact angles of the worn surface increased after friction. The friction and wear experiments were tested on a MRH-3 model ring-on-block test rig at different sliding speeds and loads under dry sliding and water lubrication. Experimental results revealed that the talc contributed to largely improve the tribological properties of the PU composites. The coefficient of friction (COF) of the composites increased with increasing talc. Scanning electron microscopic (SEM) investigations showed that the worn surfaces of the talc filled PU composites were smoother than pure polyurethane under given load and sliding speed.     

Structural and Tribological Properties of Polyimide/Al2O3/SiO2 Composites in Atomic Oxygen Environment

Effects of atomic oxygen (AO) irradiation on the structural and tribological behaviors of polyimide/Al₂O₃/SiO₂ composites were investigated in a ground-based simulation facility, in which the energy of AO was about 5 eV and the flux was 7.2 × 10¹⁵ cm^?2.s^?1. The structural changes were characterized by X-ray photoelectron spectroscopy (XPS) and attenuated total-reflection FTIR (FTIR-ATR), while the tribological changes were evaluated by friction and wear tests as well as scanning electron microscopy (SEM) analysis of the worn surfaces. It was found that AO irradiation induced the oxidation and degradation of polyimide (PI) molecular chains. The destructive action of AO changed the surface chemical structure, which resulted in changes of the surface morphology and chemical composition of the samples. Friction and wear tests indicated that AO irradiation decreased the friction coefficient but increased the wear rate of both pure and Al₂O₃/SiO₂ filled PIs.     

Friction and Wear Behaviors of the Polydimethylsiloxane Bishydroxyalkyl-Terminated Modified Polyurethane Composites Filled with the Barium Sulfate in Dry Friction and Water Lubrication

The addition of less than 20 wt% of approximate 1 micron barium sulfate (BaSO₄) into polyurethane (PU) composites modified by bishydroxyalkyl-terminated polydimethylsiloxane (PDMSBH) resulted in increases in mechanical strength and thermal conductivity and, at the same time, resulted in improvements in the friction and wear properties of the polyurethane composites. These polyurethane composites were suitable for marine use for bearings at high load under dry friction and at fast sliding speed under water lubrication. Characterization with Fourier transform infrared (FTIR) spectroscopy, thermogravimetry analysis (TGA), scanning electron microscope (SEM), and an MRH-3 ring-on-block wear tester indicated that the addition of BaSO₄ disrupts the organic phase separation in the polyurethane, resulting in better tribological properties, but there is no special chemical reaction between the particles and polyurethane. Adding too much BaSO₄ resulted in higher wear rate because of inorganic–organic phase separation.     

Synthesis of anodizing composite films containing superfine Al2O3 and PTFE particles on Al alloys

Anodized composite films containing superfine Al₂O₃ and PTFE particles were prepared on 2024 Al alloy using an anodizing method. The microstructures and properties of the films were studied by scanning electron microscopy, optical microscopy and X-ray diffraction. Friction wear tests were performed to evaluate the mechanical properties of the composites. Results indicate that the composite films with reinforced Al₂O₃ and PTFE two-particles have reduced friction coefficients and relatively high microhardness. The friction coefficient can be as small as 0.15, which is much smaller than that of an oxide film prepared under the same conditions but without adding any particles (0.25), while the microhardness can reach as high as 404 HV. When rubbed at room temperature for 20 min during dry sliding friction tests, the wear loss of the film was about 16 mg, which is about the half of that of the samples without added particles. The synthesized composite films that have good anti-wear and self-lubricating properties are desirable for oil-free industrial machinery applications.     

Characterization and tribological investigation of SiO2 and La2O3 sol–gel films

Thin films of SiO₂ and La₂O₃ were prepared on a glass substrate by a dip-coating process from specially formulated sols. The tribological properties of the resulting thin films sliding against a Si₃N₄ ball were evaluated on a one-way reciprocating friction and wear tester. The morphologies of the unworn and worn surfaces of the films were examined by an atomic force microscope (AFM) and a scanning electron microscope (SEM). La₂O₃ shows the best tribological performance. The coefficient of friction is about 0.1 and the wear life is over 5000 sliding passes both under higher (3 N) and lower load (1 N). The SiO₂ film derived from a specially formulated aqueous solution shows much better performance in resisting wear and reducing friction than the one derived from an ethanol solution. The wear mechanisms of the films are discussed based on SEM observation of the worn surface morphologies. SEM observation of the morphologies of worn surfaces indicates that the worn surface of La₂O₃ is too slight to be observed by SEM. The wear of SiO₂ derived from TEOS solution is the characteristic of delaminating, which is responsible for the abrupt failure of the film. The wear of SiO₂ derived from aqueous solution is the characteristic of fracture. Brittle fracture and severe abrasion dominate the wear of glass substrate.     

Tribological Properties of Thermosetting Polyimide/TiO2 Nanocomposites Under Dry Sliding and Water-Lubricated Conditions

Thermosetting polyimide(PI)-based nanocomposites containing various contents of nano-TiO₂ were fabricated via an in situ polymerization of monomer reactants (PMR) process. Under dry sliding and water-lubricated conditions the friction and wear behaviors of the PMR PI and its nanocomposites were evaluated and compared. The addition of nano-TiO₂ in PI contributed to improving the friction and wear behavior considerably under dry sliding. The highest change ratio of wear rate was 61% with the optimum nano-TiO₂ content of 3%, while the highest change of friction coefficient was 60% with the optimum nano-TiO₂ content of 9%. Under water-lubricated condition, contrarily, the addition of nano-TiO₂ in PI does harm to the tribological properties. Namely, the friction coefficient of the nanocomposites increased with increasing the nano-TiO₂ content. These results may be caused by the following facts: the hardness of the PI matrix would be increased by adding the nano-TiO₂ reducing the ability of elastic deformation of the nanocomposites; accordingly, the poor elastic deformation hindered the formation of a water-lubrication film on the surface. An investigation on the wear tracks indicated that the wear mechanism of PI/TiO₂ nanocomposites under dry sliding condition proceeded from fatigue wear to a combination of fatigue wear and abrasive wear with increasing the mass fraction of nano-TiO₂.     

Effects of Aramid Fiber and Polytetrafluoroethylene on the Mechanical and Tribological Properties of Polyimide Composites in a Vacuum

Polyimide composites filled with aramid fiber (AF) and polytetrafluoroethylene (PTFE) were prepared by hot press molding. The thermal, mechanical, and tribological properties of the composites were studied systematically. The friction and wear behavior, sliding against GCr15 steel balls, were evaluated in a ground-based wear in space simulation facility using a ball-on-disk tribosystem. The morphologies of the worn surfaces during the sliding process of the composites were analyzed by scanning electron microscopy to reveal the wear mechanism. It was found that the heat-resisting performance and the hardness of the composites were minimally affected by the additives. The flexural strength of polyimide/AF/PTFE (PI-3) decreased when PTFE was added. The wear resistance increased and the coefficient of friction decreased due to the effect of both fillers. In vacuum, the friction coefficients of polyimide (PI-1), polyimide/AF (PI-2), and PI-3 increased slightly with sliding velocity, while the opposite results were obtained in air. With the increase of air pressure the friction coefficients of the samples increased.     

Tribological Properties of Surface-Modified Graphene Filled Carbon Fabric/Polyimide Composites

To improve the wear resistance of carbon fabric reinforced polyimide (CF/PI) composite, surface-modified graphene (MG) was synthesized and employed as a filler. The flexural strength, Rockwell hardness and thermal properties of the composites were tested. The composites were also evaluated for their tribological properties in a ring-on-block contact mode under dry sliding conditions. The results showed that the wear rate of MG reinforced CF/PI composites was reduced when compared to unfilled CF/PI composite. It was found that the 1?wt% MG filled CF/PI composites exhibited the optimal tribological properties. The worn surface, wear debris and transfer films were analyzed by scanning electron microscopy (SEM) and optical microscopy (OM) with the results helping to characterize the wear mechanism.     

Electrodeposition and tribological properties of Ni-SrSO4 composite coatings

Ni-SrSO₄ composite coatings were electrodeposited on superalloy Inconel 718 from a Watts electrolyte containing a SrSO₄ suspension. Ni-SrSO₄ coatings were investigated by scanning electron microscope, microhardness tester, and friction and wear tester in sliding against a bearing steel ball under unlubricated condition. The incorporation of SrSO₄ into Ni matrix increases the microhardness of electrodeposited coatings. Ni-SrSO₄ composite coating exhibits a distinctly low friction coefficient and a small wear rate as contrasted with pure Ni coating and the substrate. The effect of SrSO₄ particles on microstructure and tribological properties of Ni-SrSO₄ composite coatings is discussed.     

Electrodeposition and characterization of Ni-Y2O3 composite

Nano-sized Y₂O₃ particles were codeposited with nickel by electrolytic plating from a nickel sulfate bath. The effects of the incorporated Y₂O₃ on the structure, morphology and mechanical properties (including microhardness, friction coefficient and wear resistant) of Ni-Y₂O₃ composite coatings were studied. It is observed that the addition of nano-sized Y₂O₃ particles shows apparent influence on the reduction potential and pH of the electrolyte. The incorporated Y₂O₃ increases from 1.56 wt.% to 4.4 wt.% by increasing the Y₂O₃ concentration in the plating bath from 20 to 80 g/l. XRD results reveal that the incorporated Y₂O₃ particles favour the crystal faces (2 0 0) and (2 2 0). SEM and AFM images demonstrate that the addition of Y₂O₃ particles causes a smooth and compact surface. The present study also shows that the codeposited Y₂O₃ particles in deposits decrease the friction coefficient and simultaneously reduce the wear weight loss. Ni-Y₂O₃ composite coatings reach their best microhardness and tribological properties at Y₂O₃ content 4.4 wt.% under the experiment conditions.     

Friction and wear properties of PA6 filled PTFE composites under oil lubrication

Blending polytetrafluorothylene (PTFE) to PA6 at different compositions was produced in a corotating twin-screw extruder where, PTFE acts as the polymer matrix and PA6 as the dispersed phase. The tribological properties of PTFE composites filled with PA6 under oil lubrication were investigated. The worn surface morphologies of neat PTFE and its composites were examined by scanning electron microscopy (SEM) and the wear mechanisms were discussed. The presence of PA6 particles dispersed in the PTFE continuous phase exhibited superior tribological characteristics to unfilled PTFE. The optimum wear reduction was obtained when the content of PA6 is 30 vol%.     

Composite Material Based on Polytetrafluoroethylene and Al–Cu–Fe Quasi-Crystal Filler with Ultralow Wear: Morphology,Tribological, and Mechanical Properties

Samples of composites with polytetrafluoroethylene as the matrix and a powder of 0, 1, 2, 4, 8, 16, and 32 vol % Al–Cu–Fe quasi-crystal as the filler are prepared. Electron microscopy studies of the sample structure are carried out, the influence of the filler on the degree of crystallinity and the melting and destruction temperatures of the samples is investigated; mechanical tensile tests and tribological tests are performed. The composite samples with filler contents of 4, 8, 16, and 32 vol % show ultralow wear with the coefficient K < 5 × 10^–7 mm³/N m. The highest wear resistance exceeding that of unfilled polytetrafluoroethylene by 2200–3100 times is recorded in composites with 16 vol % filler. An increase in the wear resistance is associated with formation on the friction surface of a thin crust containing quasi-crystal particles 0.2–0.3 μm in size, revealed by scanning electron microscopy in combination with energy dispersive analysis.     

Tribological behavior of Al-based self-lubricating composites

Abstract

Aluminum-based composites containing either SiC (Al10%SiC) as the hard phase or a combination of SiC and MoS₂ (Al10%SiC4%MoS₂) have been synthesized following stir casting route. To overcome the poor wetting characteristics, magnesium was added in one of the composites (Al10%SiC4%MoS₂4%Mg) to improve the bonding between matrix and second phase. The results suggested an enhancement in hardness and strength of the composite containing SiC–MoS₂ and Mg, thus indicating the effectiveness of Mg addition in improving the interfacial bonding strength. Tribological performance of the composites has been examined by carrying out pin-on-disk wear tests under dry sliding conditions at different normal loads of 9.8, 14.7, 19.6, and 24.5 N and at a constant sliding speed of 1 m/s. Both the friction coefficient and the wear rate have been found to reduce with addition of MoS₂; however, bonding between the matrix and reinforcements was not good. Al10%SiC4%MoS₂4%Mg has shown the best tribological performance at all the loads in terms of the lowest friction coefficient and the lowest wear rate. The wear mechanism has been found to be a combination of adhesion and abrasion as indicated by the presence of some abrasive grooves and delaminated flakes at the worn surface and the X-ray examination of wear debris for all the materials used in the present investigation.     

The tribology properties of alumina/silica composite nanoparticles as lubricant additives

The as-prepared alumina/silica (Al₂O₃/SiO₂) composite nanoparticles were synthesized with a hydrothermal method and modified by silane coupling agent. The tribological properties of the modified Al₂O₃/SiO₂ composite nanoparticles as lubricating oil additives were investigated by four-ball and thrust-ring tests in terms of wear scar diameter, friction coefficient, and the morphology of thrust-ring. It is found that their anti-wear and anti-friction performances are better than those of pure Al₂O₃ or SiO₂ nanoparticles. When the optimized concentration of nanoparticle additive is 0.5 wt.%, the diameters of wear scar and friction coefficients are both smallest. Such modified composite nanoparticles can adsorb onto the friction surfaces, which results in rolling friction. Therefore, the friction coefficient is reduced.     

Ultraviolet or Atomic Oxygen Effects on Tribological Properties of the Carbon Fibers/Polyimide Composites

Carbon fibers-reinforced polyimide composites (CF-PI) were fabricated by means of a hot press molding technique. To contrast the effects of ultraviolet and atomic oxygen irradiation under high vacuum on the tribological properties of CF-PI composites, the friction and wear properties of the composites sliding against GCr15 steel ball before and after irradiation were conducted in high vacuum on a ball-on-disk test rig. The experimental results revealed that CF-PI composites exhibited higher modulus and lower coefficient of friction and worn rate value than pure polyimide under high vacuum. However, the coefficient of friction of composites increased and the worn rate value decreased after ultraviolet or atomic oxygen irradiation, which slightly affected the tribological properties of CF-PI composites. The chemical composition of the composites changed after irradiation was inspected by X-ray photoelectron spectroscopy. Microstructure of the worn surfaces of the tested composites was investigated by scanning electron microscopy to reveal the wear mechanism.