Nanocomposite UHMWPE–CNT Polymer Coatings for Boundary Lubrication on Aluminium Substrates

The boundary lubrication regime plays a very important role in determining the life span of any of the two mating parts under liquid-lubricated conditions. It is during the start\stop cycles when insufficient fluid is available to fully separate the surfaces in relative motion and thus unusual wear takes place; a case of boundary lubrication. The aim of this work is to study the feasibility of using polymer coatings as boundary lubricants. This study investigates the friction and wear properties of ultra-high molecular weight polyethylene (UHMWPE) films coated on aluminium substrates under dry and base oil (without any additives)-lubricated conditions. In order to increase the load bearing capacity of the UHMWPE coatings, 0.1 wt% of single-walled carbon nanotubes are added. Experiments are carried out on a custom-built tribometer simulating a line contact between a polymer-coated cylindrical Al surface (shaft) and a flat uncoated Al plate as the counterface. The experimental parameters such as the normal load and the sliding speed are selected to simulate the boundary and mixed lubrication regimes for comparison purposes. Specific wear rates of the polymer films and bare Al surface under lubricated conditions are also calculated. Stribeck curves have been generated to evaluate the effectiveness of the pristine UHMWPE and the nanocomposite coatings in the various regimes of lubrication, especially the boundary lubrication regime. It is observed that the selected polymer coatings are effective in protecting the metallic surfaces without causing any observable oil contamination with wear debris.     

Effect of Nanoalumina on the Tribology Performance of C4-Ether-Linked Bismaleimide-Toughened Epoxy Nanocomposites

In the present investigation, C4-ether-linked bismaleimide-toughened epoxy-reinforced alumina nanocomposites were formulated. The silane-functionalized nanoparticles are covalently connected to the matrix through the reaction between epoxide groups during curing, and as a consequence, the interfacial interaction between the alumina nanoparticle and matrix was enhanced. The T _g increased with the addition of alumina nanoparticles up to 5 wt% beyond which the T _g decreased due to phase segregation. The nanoindentation studies revealed that the hardness and the elastic modulus of the nanocomposites had increased with the filler concentration up to 5 wt% beyond which it showed a decreasing trend. The wear performance of the hybrid nanocomposite was significantly lower than those of the epoxy nanocomposite. The nanocomposites with 5 wt% Al₂O₃ showed greatest improvement in wear resistance compared to higher alumina concentration, and the key factor riding the wear resistance is due to positive rolling effect phenomenon.     

Tribological Performance of UHMWPE/GNPs Nanocomposite Coatings for Solid Lubrication in Bearing Applications

Ultra-high molecular weight polyethylene (UHMWPE)/ graphene nanoplatelets (GNPs) nanocomposite coatings were developed to reduce friction and wear in the absence of liquid lubrication. UHMWPE nanocomposite powders with different loadings (0.25, 1, and 2 wt.%) of GNPs were prepared and electrostatic spraying technique was then used to deposit the nanocomposite powders on aluminum alloy to form a thin coating. Friction and wear tests were conducted on the coatings against a flat-end pin, made of hardened tool steel to determine the best loading of GNPs. That was further tested to investigate the effect of sliding speed and contact pressure on its tribological properties and to establish coating operating limits. Results showed that UHMWPE nanocomposite coating reinforced with 1 wt.% GNPs showed the best tribological performance. It reduced wear rate by about 51% as compared to the pristine UHMWPE coating. The coating sustained a maximum sliding speed of 1 m/s at a contact pressure of 4 MPa equivalent to a pressure and velocity (PV) value of 4 MPa.m/s.     

In Vacuo Tribological Behavior of Polytetrafluoroethylene (PTFE) and Alumina Nanocomposites: The Importance of Water for Ultralow Wear

Polytetrafluoroethylene (PTFE) is widely regarded as an excellent candidate for solid lubrication in vacuum. However, it is often precluded from many practical applications due to its intrinsically high wear rate. Over the past decade, it has been discovered that small loading fractions of alumina nanofillers can increase the wear resistance of PTFE by three to four orders of magnitude. This dramatic increase in wear resistance has in turn prompted numerous tribological studies to examine the robustness of this performance. In this study, the wear and friction behavior of unfilled PTFE and PTFE and alumina nanocomposites were evaluated under a broad range of vacuum environments from 760 to 4 × 10^?6 Torr. The nanocomposites of PTFE/alumina showed a dramatic increase in wear of over two orders of magnitude at the highest vacuum conditions. There appears to be an optimal vacuum environment around 1–10 Torr, in which these samples achieved the lowest wear rates of approximately 2.5 × 10^?7 mm³/(Nm).     

Pre-Polishing the Metal Counterface of Metal–UHMWPE Wear Pair with Filler-Filled UHMWPE Composites to Generate Counterface Changes for an Effective Reduction in Pure UHMWPE Wear

Ultra-high molecular weight polyethylene (UHMWPE) is well known for high-wear-resistance applications. Its long-chained easy sliding molecules and semi-crystalline structures enable the polymer’s great wear resistance. UHMWPE composites made for higher wear resistance study have been analyzed in this paper. Pure UHMWPE, 1 wt% CNT UHMWPE, 1 wt% PEEK UHMWPE, 1 wt% alumina (nano)–UHMWPE composites were made to be tested against metal disk on pin-on-disk tribometer. The metal disk surface conditions were found to have significant influence on the UHMWPE–polymer wear than the composite itself. This result indicates a simple and industrial applicable method that involves transfer film on the counterface to reduce polymer wear for metal–polymer wear pair applications.     

Tribological Behavior of Carbon Nanotube-Reinforced AZ91D Composites Processed by Cyclic Extrusion and Compression

Reciprocating wear tests were conducted to assess the wear resistance of CNT-reinforced AZ91D composites prepared by cyclic extrusion and compression (CEC). Effects of CEC, CNTs, and wear parameters on the tribological behavior of the composites were discussed. Results show that the matrix grain of the 0.5 wt% CNTs/AZ91D composites is largely refined from ~?112 µm to 126.6 nm after eight passes of CEC. Accordingly, the hardness of the composites is increased by more than 82.0%. The wear rate of the CNTs/AZ91D composites decreases with the implement of CEC and the addition of CNTs. The lubrication effect of CNTs diminishes after CEC. Besides the reinforcing effect, the incorporated CNTs help to liberate the friction heat of the CNTs/AZ91D composites and reduce the welding of the wear debris due to their extraordinary thermal conductivity.     

Effect of MWCNTs-COOH Reinforcement on Tribological Behaviors of PI/MWCNTs-COOH Nanocomposites Under Seawater Lubrication

The carboxyl-functionalized multiwalled carbon nanotube (MWCNT-COOH) was achieved by grafting carboxyl (COOH) groups onto surfaces of MWCNTs. Then polyimide (PI)-based nanocomposites reinforced with MWCNTs-COOH and MWCNTs were prepared by in situ polymerization and the tribological behaviors of PI/MWCNTs-COOH and PI/MWCNT nanocomposites were studied under dry friction and seawater lubrication. The results showed that the incorporation of MWCNTs-COOH and MWCNTs could greatly improve the wear resistance of PI because of the lubricating effect of MWCNTs-COOH and MWCNTs. In additon, the PI/MWCNTs-COOH exhibited better tribological performance than the PI/MWCNTs under dry friction due to functionalization of MWCNTs. In addition, PI/MWCNTs-COOH nanocomposites presented better tribological properties under seawater lubrication than other conditions because of the excellent lubricating effect of seawater, especially when the content of MWCNTs-COOH was 0.7 wt%. Furthermore, the effects of applied load and sliding speed on the tribological behaviors of PI/MWCNTs-COOH nanocomposites were studied under seawater lubrication. It was found that 0.7 wt% PI/MWCNTs-COOH nanocomposites had the best friction reduction and antiwear properties when the applied load and sliding speed were 3 N and 0.26 m/s, respectively, under seawater lubrication.     

Effect of UHMWPE Microparticles on the Tribological Performances of High-Strength Glass Fabric/Phenolic Laminate Composites Under Water Lubrication

The tribological behaviors of ultra-high molecular weight polyethylene (UHMWPE) microparticle-modified high-strength glass fabric/phenolic laminate composites sliding against stainless steel under water lubrication have been investigated. Results showed that the incorporation of UHMWPE microparticles, especially at the mass fraction of 5.0 %, improved the wear resistance of the laminate composite to a significant extent, because UHMWPE microparticle can effectively absorb and dissipate the friction energy through a plastic deformation during the formation of the regular ripple-like abrasion patterns on its worn surface. During the sliding process, after the phenolic resin was firstly worn off, UHMWPE microparticles with much better wear resistance were protruded from the worn surface of the laminate composite, leading to a fundamental change in the contact status of the matched surfaces from rigid resin and fibers/steel to flexible UHMWPE/steel. As a result, low and steady friction coefficient was obtained due to good adaptability of UHMWPE to water lubrication.     

Antifrictional composites based on chemically modified UHMWPE. Part 2. The effect of nanofillers on the mechanical and triboengineering properties of chemically modified UHMWPE

The mechanical and tribological properties of nanocomposites based on chemically modified ultra-high molecular weight polyethylene are determined. The super-molecular and chemical structure of the nanocomposites based on the block copolymers UHMWPE-grafted UHMWPE and UHMWPE-grafted HDPE are studied by the methods of X-ray structural analysis, IR spectroscopy, scanning differential calorimetry, and electron microscopy. The mechanical and tribological properties of the nanocomposites based on the block copolymers are found to differ insignificantly from those of the nanocomposites on the base of non-modified UHMWPE. The crystallization and formation of super-molecular structure in the heterogeneous materials under study are shown to depend on the heterogeneity of the distribution of the nanofillers. The authors believe that chemical modification in terms of grafting polar monomers is unable to improve the adhesion of the nanofillers to the high-molecular matrix (UHMWPE). Thus, the wear resistance of the UHMWPE-based nanocomposites is mostly governed by the crystallization conditions and type of supermolecular structure formed during crystallization (either spherulitic or lamellar).     

Tribological Behavior of Polyamide 66-Based Ternary Nanocomposites Modified with Organoclay and SEBS-<Emphasis Type="Italic">g</Emphasis>-MA

The tribological behavior of polyamide 66 (PA66) nanocomposites consisting of styrene–ethylene/butylene–styrene triblock (SEBS-g-MA) particles and organoclay was studied. It was found that the blending sequence significantly influences the wear resistance of PA66/SEBS-g-MA/organoclay nanocomposites, and the PA66 + (SEBS-g-MA + organoclay) nanocomposite has the biggest d-spacing of organoclay nanolayers and the best wear resistance.     

Friction and Wear Behavior of Ultra-High Molecular Weight Polyethylene Sliding Against GCr15 Steel and Electroless Ni–P Alloy Coating Under the Lubrication of Seawater

The friction and wear behavior of ultra-high molecular weight polyethylene (UHMWPE) sliding against GCr15 steel and electroless Ni-P alloy coating under the lubrication of seawater was investigated and compared with that under dry sliding and lubrication of pure water and 3.5 wt.% NaCl solution, respectively. It was found that under the lubrication of aqueous medium, the friction and wear behavior of UHMWPE mainly depended on the corrosion of counterface and the lubricating effect of the medium. Because of serious corrosion of counterface by the medium, the wear rates of UHMWPE sliding against GCr15 under the lubrication of seawater and NaCl solution were much larger than that under other conditions, and such a kind of wear closely related to the corrosion of counterface can be reckoned as indirect corrosive wear. However, when sliding against corrosion-resistant Ni–P alloy under the lubrication of seawater, the lowest coefficient of friction and wear rate of UHMWPE were obtained, owing to superior lubricating effect of seawater. Moreover, periodic ripple patterns were observed on the worn surfaces of UHMWPE sliding against GCr15 under the lubrication of seawater and NaCl solution, which were ascribed to the intelligent reconstruction of surface microstructure of UHMWPE upon large plowing effect of the counterface asperities. Based on scanning electron microscopic (SEM) and three-dimensional (3D) profile analyses of the worn surfaces of UHMWPE, a stick–slip dynamic mechanism was proposed to illustrate the pattern abrasion of UHMWPE. Electronic supplementary material  The online version of this article (doi:) contains supplementary material, which is available to authorized users.     

Friction and wear properties of UHMWPE/Al2O3 ceramic under different lubricating conditions

Friction and wear behavior of ultra-high molecular weight polyethylene (UHMWPE) sliding against Al₂O₃ ceramic under dry sliding, and lubrication of fresh plasma, distilled water and physiological saline were investigated with a self-made pin-on-disk apparatus at 37±1°C. The worn surfaces were examined with a scanning electron microscope (SEM). The results show that the friction behavior of UHMWPE is very sensitive to its water absorption state. The wear rate of UHMWPE under dry sliding is the highest and under plasma lubrication is the lowest. The wear mechanisms are different under dry friction and various lubricating conditions.     

Wear resistance of composites based on ultrahigh molecular weight polyethylene filled with graphite and molybdenum disulfide microparticles

Tribological characteristics of ultrahigh-molecular-weight polyethylene (UHMWPE)-based compositions with graphite and molybdenum disulfide are studied under conditions of dry friction, boundary lubrication, and abrasive wear. It is shown that, under dry sliding friction, the wear rate of UHMWPE-graphite and UHMWPE-MoS2 polymer compositions is halved as compared to that of pure UHMWP, while their mechanical characteristics change only slightly. Under the conditions of abrasive wear, the wear resistance of these composites increases by 1.3–1.5 times. Concentrations of the fillers, which are optimum for improving the wear resistance, are determined. The supramolecular structure and the topography of worn surfaces of the UHMWPE compositions with various concentrations of the fillers are examined. A comparative analysis of the wear resistance of the composites under conditions of dry friction and lubrication is carried out. Mechanisms of the wear of the UHMWPE-graphite and UHMWPE-MoS₂ polymer compositions under conditions of dry sliding friction and abrasive wear are discussed.     

多孔UHMWPE软骨材料润滑性能的Stribeck研究

采用T-L法制备出仿生多孔UHMWPE材料,测试了其与水的接触角;在不同的摩擦学条件下测试了普通UHMWPE和多孔UHMWPE试样与不锈钢接触时的润滑性能,并利用Stribeck润滑曲线分析了其润滑状态。结果表明:多孔结构能提高UHMWPE的亲水性能;水润滑条件下,普通UHMWPE表面只能形成边界润滑区域;仿生多孔UHM-WPE具有的多孔结构使得在高速低条件下能形成混合润滑区域,降低材料的摩擦磨损行为;牛血清润滑下普通UHM-WPE的润滑情况变化不大,多孔UHMWPE试样的Stribeck曲线谷底较宽,说明比水润滑条件下具有更好的润滑性能。     

Friction and dry sliding wear of bismaleimide filled with carbon nanotubes

Three types of bismaleimide–carbon nanotubes (CNTs) nanocomposites were fabricated using two types of original multiwalled CNTs with different diameters and one amide functionalized CNTs. The influence of diameter, content and functionalization of CNTs on the flexural and dry sliding wear behaviour were measured with universal testing machine and pin-on-disc wear apparatus. The experimental results indicated that at 1.5 wt-%, the bismaleimide-functionalized MWCNTs exhibited highest flexural strength of 156 MPa which is increased by 164% as compared to the neat matrix, and lowest specific wear rate of 1.8 × 10^?4 mm³ N^?1 m^?1 which is decreased by 90% as compared to the neat matrix. This was attributed to the dispersion of CNTs in the matrix and the filler-matrix adhesion and internal strength of the composite.     

Effect of Carbon Nanotube Addition on Tribological Behavior of UHMWPE

Carbon nanotubes (CNTs) were added to Ultra-high molecular weight polyethylene (UHMWPE) to improve the tribological properties of UHMWPE. CNTs which have a diameter of about 10–50 nm, while their length is about 3–5 nm were produced by the catalytic decomposition of acetylene gas using a tube furnace. Ball-on-disc-type wear tests were performed to evaluate the tribological performance of UHMWPE composites reinforced with CNTs. The results showed that addition of carbon nanotube up to 0.5 wt% lowered wear loss significantly and increased friction coefficient slightly. Also through the scanning electron microscope (SEM), the surfaces of UHMWPE were observed and analyzed to discuss the tribological behavior of CNT added UHMWPE.     

UHMWPE基水润滑轴承摩擦及润滑特性的试验研究

针对纤维填料改性UHMWPE水润滑轴承的摩擦磨损性能进行研究。在平面摩擦磨损试验机上对玻璃纤维及碳纤维填料对UHMWPE复合材料摩擦性能进行试验,并分析GF-CF-UHMWPE材料与Thordon SXL材料在干摩擦、水润滑工况下的摩擦因数及磨损量。最后,采用径向水润滑轴承试验台对比研究了GF-CF-UHMWPE轴承和Thordon SXL轴承在不同载荷下摩擦因数随转速的变化规律。结果表明:纤维填料能显著增强UHMWPE的减摩性和耐磨性,GF-CF-UHMWPE材料具有更好的耐温性能,线性热膨胀系数也显著减小;GF-CF-UHMWPE轴承具有相同载荷下启动转速低,启动摩擦因数小的特性。     

Self-lubricating SU-8 Nanocomposites for Microelectromechanical Systems Applications

SU-8 is an industrially useful photoresist polymer for micro-fabrication because of its unique UV-sensitive curing property. It is also used as a structural material for micro-machines such as micro-electro mechanical systems (MEMS). However, it has poor tribological and mechanical properties which make SU-8 inferior to Si, the mainstay MEMS material today. In this paper, we report the fabrication of SU-8 nanocomposites which are self-lubricating and have better mechanical properties. The liquid lubricant i.e., perfluoropolyether (PFPE) and nanoparticles such as SiO₂, CNTs, and graphite were added into SU-8 for this purpose. These self-lubricating SU-8 + PFPE and SU-8 + PFPE + nanoparticle composites have shown a reduction in the initial coefficient of friction by ~6?C9 times and increased wear life by more than four orders of magnitude. The mechanical properties such as the elastic modulus and the hardness have increased by ~1.4 times. These SU-8 nanocomposites can be used as a self-lubricating structural material for MEMS applications requiring no external lubrication. As well, these nanocomposites can find applications in many tribological components of traditional machines.     

Effect of Load and Composition on Friction and Dry Sliding Wear Behavior of Tungsten Carbide Particle-Reinforced Iron Composites

Investigations on the dry sliding wear behavior of tungsten carbide (WC)-reinforced iron matrix composites were carried out at room temperature. Three sets of samples (unreinforced iron, 4 wt% micrometer-size (～5–15 μm) WC-reinforced iron and 4 wt% nanosize (～30 nm) WC-reinforced iron were prepared using a powder metallurgy route to assess their friction and wear behaviors under two different loads. The relative dry sliding wear performances of the micrometer-size and nanosize WC-reinforced composites were compared with unreinforced matrix. An increase in microhardness of the order of 2.5 times was observed in the case of 4 wt% nanosize WC-reinforced iron matrix compared to the unreinforced iron matrix. The wear rate was 1.35 to 1.45 times lower in the case of nanocomposites compared to the unreinforced iron matrix (under different experimental conditions). The values of the coefficient of friction (COF) of composites were found to decrease with increase in load. Nanocomposites showed lower COF, surface roughness, and fractal dimension (D) values than micrometer-size WC-reinforced composites and the unreinforced iron matrix.     

Dry sliding wear properties of unhybrid and hybrid Al alloy based nanocomposites

Abstract

Nanosize B₄C and/or MoS₂ particles reinforced AA2219 alloy composites were prepared using the stir casting process. The wear properties were evaluated for several speed (3.14–5.65 m s^?1), load (10–50 N) and distance (0–2500 m) conditions. The nanoparticles dispersion, density, wear resistance, morphology of the worn surface and loose wear debris were discussed in detail. The wear resistance improvement results by nanoparticle addition correspond well with the hardness. Between the nanocomposites, hybrid composites show significantly higher wear resistance for all load, speed and sliding distance conditions. The better wear resistance is attributed to the matrix strengthening by nanoparticles and the lubricant-rich tribolayer controlled wear in the hybrid composites. The intensity of abrasive, oxidation and delamination wear mechanisms decide the wear rate at any particular wear testing condition.