Influence of surface roughness and contact load on friction coefficient and scratch behavior of thermoplastic olefins

To study the effects of surface roughness and contact load on the friction behavior and scratch resistance of polymers, a set of model thermoplastic olefins (TPO) systems with various surface roughness (R_a) levels were prepared and evaluated. It is found that a higher R_a corresponds to a lower surface friction coefficient (μ_s). At each level of R_a, μ_s gets larger as contact load increases, with a greater increase in μ_s as R_a level increases. It is also observed that with increasing contact load and increasing R_a, the μ_s tend to level off. In evaluating TPO scratch resistance, a lower μ_s would delay the onset of ductile drawing-induced fish-scale surface deformation feature, thereby raising the load required to cause scratch visibility. However, as the contact load is further increased, the μ_s evolves to become scratch coefficient of friction (SCOF) as significant sub-surface deformation and tip penetration occur and material displacement begins, i.e., ploughing. No dependence of R_a and μ_s on the critical load for the onset of ploughing is observed. In this work, the distinction between μ_s and SCOF will be illustrated. Approaches for improving scratch resistance of polymers via control of R_a are also discussed.