Tribological and mechanical properties of composites based on ethylene-tetrafluoroethylene and quasicrystalline Al−Cu−Fe filler

Samples of composites, in which ethylene-tetrafluoroethylene copolymer is used as a matrix and quasicrystalline Al?Cu?Fe powder as a filler with 0, 1, 2, 4 and 8 vol % concentrations, are prepared. Electron microscopy studies of the sample structure are carried out. The influence of the filler on the crystallinity and temperatures of sample melting and destruction is investigated. The mechanical and tribological properties of the samples are tested. It is found that an increase in the filler content changes neither the mechanical nor thermodynamic characteristics of the material but significantly improves the tribological characteristics. The friction coefficient decreases twice at 1 vol % of the filler and the wear resistance increases by 40 times at 8 vol %. Experimental data indicate the probability of good adhesion of the filler particles to the fluoropolymer matrix. The composites under investigation may be of interest as promising materials for polymer friction bearings.     

Abrasive Wear Behavior of LDPE Filled with Silane Treated Flyash Cenospheres

Lightweight, high mechanical strength insulating materials exhibiting high resistance to corrosion, solvents and abrasive wear are desired for wire and cable insulation as well as protection. Polyethylenes are generally used for such applications owing to their good electrical insulation properties and being inert to solvents at room temperature. However, their abrasion resistance is quite poor. Hence, in the present work, an attempt has been made to improve the abrasive wear resistance of low-density polyethylene (LDPE) by incorporating hollow microspheres, known as cenospheres, in the base polymer to form composites. These cenospheres are obtained from flyash particles, a thermal power plant waste, and do not tend to increase the weight of the polymer composite when used as a filler. The composites were developed by changing the weight fraction of untreated as well as silane treated cenospheres to the extent of 5 wt%. Tribological characterization of these composites was done in abrasive wear mode by varying the operating parameters, such as speed and sliding distance against silicon carbide paper. It was found that 10 wt% silane treated cenosphere filled LDPE composite showed the maximum wear resistance (～×10^?11 m³/N m) among the six composites. However, a further increase in filler concentration decreased the wear resistance. The improvement in wear resistance was supported by scanning electron microscopy and attributed to the strong interaction between silane treated cenosphere and LDPE molecules which resisted the elongation and shearing of polymer chains by the abrasive grits.     

Fracture of composites based on polyethylene and elastic particles

The composites based on low-density polyethylene with elastomer filling particles are studied. A fracture mechanism induced by the fracture of filler particles or their separation from the matrix polymer is revealed. The fracture of the composites is caused by the growth of formed rhombic pores. The natural relative elongation in a neck is shown to be an important characteristic of a polymer. If the relative elongation in a neck is lower than the strain of appearance of rhombic pores, they form at the stage of uniform tension after necking, and the composite remains plastic. If the relative elongation in a neck is higher than the strain of formation of rhombic pores, they nucleate during necking, and the material undergoes quasi-brittle fracture. Good adhesion between the matrix polymer and elastic particles hinders the appearance of rhombic pores in a neck and, thus, retains high deformation properties of the composites.     

Investigation of the structure of a polyimide modified by hyperbranched polyorganosiloxanes

Polymer composites based on polyimide and hyperbranched polyorganosiloxanes have been irradiated by oxygen plasma imitating exposure to atomic oxygen in low near-earth orbits. It is demonstrated that the irradiation of composites gives rise to the generation of silicon dioxide particles distributed over the volume of the polymer matrix, promoting enhanced resistance of the materials to the action of atomic oxygen. The structures of the samples are investigated via dielectric and IR spectroscopies. It has been ascertained that introduced modifiers lead to the formation of regions with an increased ordering of polyimide chains around filler particles.     

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.     

Fractal and structural aspects of adhesion in particulate-filled polymer composites

Two types of composites based on poly(hydroxy ether) and graphite with various amounts of a filler have been investigated by various methods. The methods have been used to estimate the characteristics of adhesion and interfacial layer, including its thickness and tensile strength and interdependence between these values and adhesion. The results are treated on the basis of the theory of irreversible aggregation, cluster theory of the polymer structure and fractal analysis. It is established that all important characteristics of adhesion, interfacial layer and mechanical properties are interconnected with the difference between fractal dimensions of the surface of the aggregates of filler particles and of a polymer matrix, whose structure is distorted under the influence of the filler surface.     

Quantum mechanics simulation and experimental study of adhesive interaction and aggregation of carbon-silicate nanoparticles—reinforcing fillers of polymer composites

Nanoparticles are widely used as polymer composite-reinforcing additives—fillers. Understanding the interaction mechanisms and regularities responsible for nanoparticle aggregation is of great significance for elucidating the nature of reinforcing of polymer composites. The paper reports on quantum mechanics calculations and full-scale experimental study of adhesive interaction of carbon and silicate adsorption complexes (nanomodels of active filler particles of polymer composites). The quantum mechanics approach allowed describing the adhesive properties of particle aggregates reasoning from nanoscopic structure of their surface. The quantum mechanics data were checked for adequacy on schungite—a natural mineral containing carbon and silicate. Schungite microparticles were milled to nanosizes by colloidal grinding in various disperse liquid media (alcohol, acetone, water) and the structure and properties of aggregated schungite micro- and nanoparticles were studied; fractal analysis of their surface was performed. It is found that smaller aggregates of silicate and carbon particles with higher surface fractal dimension are formed in colloidal grinding with small molecular sizes of disperse media (in our case, ethanol or methanol) and this agrees with the data predicted by quantum mechanics calculations.     

Use of flow microcalorimetry and dynamic mechanical thermal analysis for probing interphase structure in poly(styrene-b-butadiene-b-styrene)/magnesium hydroxide composites

Interactions between magnesium hydroxide (Mg(OH)₂ particles (both untreated and treated with 16-methyl heptadecanoic acid (isostearic acid)) and low molar mass poly(styrene) (PS) and poly(butadiene) (PB) have been studied by flow microcalorimetry (FMC) and have been related to the interphase structure in poly(styrene-b-butadiene-b-styrene) (SBS)/Mg(OH)₂ composites using dynamic mechanical thermal analysis (DMTA). The FMC studies revealed that both polymers adsorbed strongly onto an untreated magnesium hydroxide surface though the PB showed greater irreversible adsorption from the heptane carrier fluid. Diffuse reflectance Fourier transform infrared spectroscopy (DRIFTS) studies on filler samples removed from the FMC cell after the adsorption-desorption cycle confirmed strong polymer filler interaction. Adsorption of the low molar mass samples of PS and PB onto a pre-adsorbed monolayer of isostearic acid on Mg(OH)₂ resulted in a very significant reduction in polymer adsorption activity due to blockage of adsorption sites. DMTA studies revealed that strong adsorption of PS and PB blocks of SBS onto untreated filler in composites containing 60% w/w Mg(OH)₂ gave rise to phase mixing that led to an 18 °C reduction in the T _g of the PS phase relative to that in the unfilled matrix. However, in equivalent composites based on isostearic acid treated filler a smaller reduction (10 °C) was observed, therefore reflecting reduced filler-matrix interaction and reduced phase mixing.     

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%.     

Taguchi approach for characterization of three-body abrasive wear of carbon-epoxy composite with and without SiC filler

Fiber–matrix interfacial bonding plays a critical role in controlling performance properties of polymer composites. Carbon fibers have major constraints of chemical inertness with the matrix and need the surface treatment to improve the adhesion with the matrix. In this work, parametric appraisal of three-body abrasive wear behavior was presented for silane treated carbon fabric reinforced epoxy (C-E) composites with and without silane treated silicon carbide (SiC) as filler. The fiber content was fixed at 60?wt.%, while the weight fraction of SiC was varied (5 and 10?wt.%) to obtain three different compositions. Three-body abrasive wear tests were conducted using design of experiments approach based on Taguchi’s orthogonal arrays. The findings of experiments indicate that the wear loss is greatly influenced by load and grain size of abrasive. An optimal parameter combination was determined, which leads to maximization of abrasion resistance. Inclusion of SiC filler reasonably increased the abrasion resistance of C-E composite. Analysis of variance results showed that the load significantly influenced the abrasion of SiC filled C-E composites. Efforts were also made to correlate the abrasive wear performance of SiC filled C-E composites using artificial neural network (ANN). The wear behavior of composite by ANN prediction closely matched the experimental results and finally, optimal wear settings for minimum wear were identified.     

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.     

Metal-Filled Epoxy Composites: Mechanical Properties and Electrical/Thermal Conductivity

Abstract

The mechanical properties and the electrical and thermal conductivity of composites based on an epoxy polymer (EP) filled with dispersed copper (Cu) and nickel (Ni) were studied. It was shown that the electrical conductivity of the composites demonstrated percolation behavior with the values of the percolation threshold being 9.9 and 4.0?vol.% for the EP-Cu and EP-Ni composites, respectively. Using the Lichtenecker model, the thermal conductivity of the dispersed metal phase in the composites, λ_f, was estimated as being 35?W/mK for Cu powder and 13?W/mK for Ni powder. It was shown that introduction of the filler in EP led to a decrease in the intensity of the mechanical loss tangent (tan δ) peak that was caused by the existence of an immobilized polymer layer around the filler particles which did not contribute to mechanical losses. Using several models the thickness of this layer, ΔR, was estimated. The concept of an “excluded volume” of the polymer, V_ex, i.e. the volume of the immobilized polymer layer, which does not depend on the particle size and is determined solely by the value of the interaction parameter, B, was proposed.     

Kinetics of friction and wear of polymer composite materials

The kinetics of wear, heating, and relaxation of the friction force of antifriction self-lubricating polymer composite materials with metals are investigated. Heat-resistant polyheteroarylenes are used as a matrix. The fillers are metal and polymer powders, TiO₂ whiskers, and strips of oriented polymer fibers. It is established that the temperature and pressure dependences of the heating rate, wear, and relaxation of the friction force are described by the Zhurkov equation. The activation energy of these processes is equal to the activation energy of fracture of the matrix. The activation volume of fracture depends on the nature and shape of the filler particles. It is concluded that the kinetics of wear, heating, and relaxation of the friction force are determined by the probability of occurrence of destructive thermal fluctuations responsible for the breaking of chemical bonds in molecules of the matrix.     

Structure of filled linear polyethylene

The structure of linear polyethylene filled with various solid particles (glass beads, silica, kaolin) was examined by using scanning electron microscopy. The mode of attachment of filler particles to semicrystalline polymer was of particular interest. The filler particles were bonded to polymer by polyethylene fibrillar links whose number depended upon the properties of the filler.     

Morphology and percolation conductivity of polymer blends containing carbon black

The structure of the polymers polypropylene (PP), polyethylene (PE), and poly-(oxymethylene) (POM) and the blends PE-PP and PE-POM containing carbon black (CB) were studied. It was found that spatial distribution of CB depends on the interface interactions between the components of composites. It is possible to obtain three cases of filler spatial distribution: Filler can be distributed randomly within the polymer matrix, can be contained in one of the polymer components, or can be localized on the polymer-polymer boundary. The conditions of various filler distribution in the heterogeneous polymer matrix are given. The correlation between morphology of the composites and their percolation conductivity was found.     

Structure and properties of thin-film metal-poly(p-xylylene) hybrid nanocomposites

Thin-film hybrid metal-poly(p-xylylene) composites synthesized by vacuum co-condensation were examined. It was demonstrated that the structure of the composites consists of a matrix comprised of polymer globules and inorganic filler nanoparticles. The shape, structure, and size of the polymer globules depend on the film thickness and the nature of the filler nanoparticles. Studying the conductivity of these materials demonstrated that it is determined by hopping conduction via surface states of the matrix. At high frequencies of the voltage applied (above 500 Hz), the electric conduction characteristics depend appreciably on the processes of recharging of the surface states of the matrix and of the nanoparticle-matrix interfaces. Tests of lithium battery anodes prepared from nanocomposites showed that these materials are promising for manufacturing chemical current sources.     

Study on the Tribological Properties of Carbon Fabric Reinforced Phenolic Composites Filled with Nano-Al2O3

Carbon fabric reinforced phenolic (CFRP) composites filled with nano-Al₂O₃ were prepared by a dip-coating and heat molding process and the tribological properties of the resulting composites under different sliding conditions were investigated systematically on a block-on-ring test rig. The worn surfaces were observed in a scanning electron microscope (SEM) to understand the mechanism. Nano-Al₂O₃ particles, as the filler, were effective in reducing the friction coefficient and wear rate of the CFRP composites. The steady state friction coefficient of the CFRP composites filled with 4 wt.% nano-Al₂O₃ particles was about 65.5% of that of unfilled CFRP composites, and the wear rate, in this case, was about 74.7% of that of unfilled CFRP composites. Tribological tests under different sliding conditions revealed that the filled CFRP composites seemed to be more suitable than unfilled CFRP composites for tribological applications under higher sliding speed and load. Moreover, the wear resistances of the unfilled and filled CFRP composites were found to be related to the stability of the transfer film on the counterface.     

The influence of particle distribution and interphase on the thermal expansion coefficient of particulate composites by the use of a new model

In this work, the thermal expansion coefficient (CTE) of a composite containing spherical particles surrounded by an inhomogeneous interphase embedded in an isotropic matrix is evaluated by means of a new model. The thermomechanical properties of the interphase are formulated as continuous radial functions. It is assumed that this third phase developed between the polymeric matrix and the filler particles contains both areas of absorption interaction in polymer surface layers onto filler particles as well as areas of mechanical imperfections. It can be said that the concept of boundary interphase is a useful tool to describe quantitatively the adhesion efficiency between matrix and particles and that there is an effect of this phase on the thermomechanical properties of the composite. The thickness and volume fraction of this phase were determined from heat capacity measurements for various filler contents. On the other hand, it is assumed that the particle arrangement (distribution) which can be considered as an influence of neighboring inclusions and their interaction should affect the thermomechanical constants of the composite. The theoretical predictions were compared with experimental results as well as with theoretical values from expressions obtained from other workers and they were found to be in satisfactory agreement.     

Reaction-Induced Phase Separation and Structure Formation in Polymer Blends

The peculiarities of reaction-induced phase separation and the structure formation in semi- and full interpenetrating polymer networks and in the blends of linear polymers formed in situ are analyzed. It is shown that for most of these systems phase separation proceeds viathe spinodal decomposition mechanism resulting in the formation of interconnected spatially periodic structures. The possible ways for the structure regulation of the composites produced are considered.     

Phase transformation studies in unirradiated and proton beam irradiated Ni–Ti alloy between 25 and 100°C

The stress-induced phase transformation characteristics of unirradiated and proton beam irradiated NiTi alloy were investigated at different tests temperatures. The wire-shaped NiTi specimens were irradiated by 2?MeV proton beam for 30?min at room temperature to a flux of 10¹⁹ protons/m² s. Engineering stress–strain (S-S) curves of both unirradiated and irradiated specimens were obtained using a materials testing machine at 25, 50, 75 and 100°C. The results indicate a single-stage phase transformation from austenite to martensite (B2–B19′) in unirraidated specimens at all the test temperatures. In contrast, in the case of the irradiated specimens, a two-stage austenite–rhombohedral–martensite (B2–R–B19′) phase transformation is observed at 25 and 50°C. The B2–R–B19′ phase transformation, however, is found to change into B2–B19′ transformation at 75 and 100°C. The stress required to initiate the B19′ phase transformation (σ_MS) and the plateau range are found to be lower in irradiated specimens compared with those of the unirradiated specimens. The results obtained are discussed on the basis of the formation of Ni₄Ti₃ precipitates in irradiated specimens and their consequences on the phase transformations.