On dry sliding friction and wear behaviour of PEEK and PEEK/SiC-composite coatings

In this work, polyetheretherketone (PEEK) and PEEK/SiC-composite coatings were deposited on Al substrates using a printing technique to improve their surfaces performance. The objective of this work was to investigate coatings friction and wear behaviour. Especially, the effect of sliding velocity and applied load on coatings friction coefficient and wear rate was evaluated in range of 0.2-1.4 m/s and 1-9 N, respectively. Compared to Al substrate, the coated samples exhibit excellent friction coefficient and wear rate. For PEEK coating, under an applied load of 1 N, the increase in sliding velocity can result in decreasing of friction coefficient at a cost of wear resistance. Under a load of 9 N, however, PEEK coating exhibits the highest friction coefficient and wear rate at an intermediate velocity. These influences appear to be mainly ascribed to the influence of contact temperature of the two relative sliding parts. In most test conditions, the composite coating exhibits better wear resistance and a little higher friction coefficient. SiC reinforcement in composite coating plays a combined role. First of all, it might lead to energy dissipation for activation of fracture occurred on the interface of PEEK and the powders. Moreover, it can reduce coating ploughs and the adhesion between the two relative sliding parts.     

Effect of temperature on the friction and wear of heat-resistant polymer-based composites

The friction and wear of polyether sulphone (PES: ‘Victrex’-ICI), polyether etherketone (PEEK: ICI), polyamide-imide (PAI: Torlon'-Amoco) and Polytetrafluoroethylene (PTFE) composites were measured at a constant sliding speed and under a constant load at various temperatures up to 300 °C by rubbing against a steel disc. The frictions of the composites, except for some PAI composites, were generally little dependent upon temperature over a wide range of temperature. PTFE filler was effective in reducing the wear of composites at high temperatures. However, the addition of various fibres to the composites was not effective at high temperatures. The wear of PAI composites increased rapidly with increasing temperature and thus their temperature variations were considerably greater than those of the other composites. The wear of PTFE containing ‘Econol’ E–1 OI, a polyoxybenzylene nomo-polymer (Sumitomo Chemical Co.) and graphite was similar to that of the PEEK composite containing PTFE, and their wear rates were remarkably low over a wide range of temperature. The wear-reducing mechanisms of PTFE and ‘Econol’ fillers are discussed on the basis of microscopic examinations of the frictional surfaces.     

Wear of PEEK composites related to their mechanical performances

A series of polyetheretherketone-based composites was investigated, blended with different contents of polytetrafluoroethylene and/or graphite, and reinforced with various amounts of short carbon fibres. The mixture of the PEEK with various fillers was achieved by twin-screw-extruders. Thereafter, the composites were finally manufactured using an injection moulding machine. Testing of the tribological properties of the PEEK composites was carried out on a block-on-ring apparatus. The dependence of mechanical properties, e.g. Charpy impact resistance, fracture toughness, flexural modulus and strength, on various filler contents of these composites was also investigated, which is believed to be of help towards a better understanding of the steps on how to improve the composite’s wear resistance.     

On the effect of counterface material and aqueous environment on the sliding wear of various PEEK compounds

Polyetheretherketone (PEEK) compounds containing carbon fibres (CF), glass fibres (GF), PTFE, and graphite, respectively, were exposed to unidirectional sliding against various counterparts (100Cr6, X5CrNi18-10, alumina, and bronze). Some of these tests were repeated in water. The stainless steel revealed the best results under dry conditions, whereas alumina was the best counterpart in water. The compound containing GF plus PTFE performed best under dry conditions. Under wet conditions, CF were superior to GF, which react very susceptibly to water. The aqueous environment usually accelerated the compound wear. Only in case of CF containing compounds sliding against alumina, the water lubrication reduced the wear rate.     

Reciprocating sliding wear of 9% Cr steel in carbon dioxide at elevated temperatures

Experiments were conducted on the initial stages of reciprocating sliding wear of a 9% chromium steel in an environment of carbon dioxide at temperatures in the range 200 to 550°C. At ambient temperatures of 290°C and above, an initial severe wear mode was followed by a transition to mild oxidational wear. At any given ambient temperature above 290°C, the distance of sliding required to reach such a transition was found to depend on load and mean sliding speed, although the dependency on speed was not simple. When a transition occurred, most of the surfaces were covered with a stable oxide film which consisted of an agglomerate layer of wear debris being mainly of oxide at the surface and mainly at the metal boundary. This film was supported by a work hardened layer extending for about 30 μm into the bulk of the metal. A surface model is proposed to explain the mechanism of formation of the supportive oxide layer; predictions of volume of material removed and final oxide coverage at the transition are in close agreement with experimental values     

On the wear debris of polyetheretherketone: fractal dimensions in relation to wear mechanisms

It has been recognized that wear debris contains extensive information about wear and friction of materials. Investigation of wear debris is important for tribological research. In order to find out an effective way that is able to diagnose and predict the wear state of polymers, the authors investigated the relationship between the wear debris morphology and the wear behaviour of the bulk material. Polyetheretherketone (PEEK) was employed as the model material. Its sliding wear and friction properties were measured by means of a pin-on-disc apparatus. At a constant sliding velocity of 1 m s⁻¹, the specific wear rate was independent of load under lower loading conditions (1–4 MPa) but increased with a rise in load under higher loading conditions (4–8 MPa). The coefficient of friction was insensitive to the variation of contact pressure. The possible mechanisms involved were analysed on the basis of the wear debris morphology as well as the wear performance. Fractal geometry, which describes non-Euclidean objects, was applied to the quantitative analysis of the boundary texture of the wear debris due to the fact that the qualitative assessment of the wear debris morphology was not effective enough to reflect the geometrical variation of the fragmental shapes. The experimental results demonstrated that the wear debris were fractals, and could be characterized with the fractal dimensions which were determined by the slit island method. In addition, it was found that the fractal dimension of the wear debris was closely related to the wear behaviour of PEEK, and can be regarded as a measure of wear rate.     

The friction and wear properties of nanometre SiO2 filled polyetheretherketone

Nanometre SiO₂ filled-polyetheretherketone (PEEK) composite blocks with different filler proportions were prepared by compression moulding. Their friction and wear properties were investigated on a block-on-ring machine by running a plain carbon steel (AISI 1045 steel) ring against the composite block. The morphologies of the wear traces and the transfer film were observed by scanning electron microscopy (SEM). It was found that nanometre SiO₂ filled-PEEK exhibited considerably lower friction coefficient and wear rate in comparison with pure PEEK. The lowest wear rate was obtained with the composite containing 7.5 wt.% SiO₂. The SEM pictures of the wear traces indicated that with the frictional couple of carbon steel ring/composite block (fillec with 7.5 wt.% filler), a thin, uniform, and tenacious transfer film was formed on the ring surface. It was inferred that the transfer film contributed largely to the decreased friction coefficient and wear rate of the filled PEEK composites.     

Effect of testing conditions on friction and wear of a polyetheretherketone-based composite

Friction and wear characteristics of a type of polyetheretherketone (PEEK)- based composite were evaluated under two different loading pressures and sliding speeds (P = 1.0 MPa, V = 1.0 m/s and P=2.0 Mpa, V=3.3 m/s). The material was in contact with steel surfaces of two different roughnesses (Ra=0.15 μm and Ra=0.33 μm). Interface temperature, coefficient offriction, depth wear rate, and specific wear rate of the polymer composite changed considerably with the PV value and the counterface roughness. The interface temperature increased with increasing PV value, whereas the friction coefficient decreased. The depth wear rate at the higher PV value was much higher than that at lower PV. In addition, the rougher counterface resulted in a higher friction coefficient, depth wear rate, and specific wear rate, when the PV value was fixed. The effect of counterface roughness on the specific wear rate at the higher PV value was smaller than that at the lower PV. Further variations in friction and wear with testing conditions are discussed along with the corresponding microscopic observations of the worn polymer surfaces and the polymer transferred counterfaces.     

Mechanisms of sliding wear of metals and alloys at elevated temperatures

Sliding wear at elevated temperature is an important material removal mechanism in large number of engineering applications such as metal forming operation, gas turbine engines, etc. The material loss during sliding at elevated temperature is governed by the antagonistic effect of wear process and oxidation. The objective of the present work is to give an outline of the current status and future trends of wear at elevated temperature of selected metallic materials. Starting with a brief overview of present level of understanding of the elevated temperature wear of various metals and alloys, the initial parts of the paper describes various important development in recent years on elevated temperature sliding wear. The salient features which have helped us to gain in depth scientific knowledge of elevated temperature wear are discussed in the light of recent developments. The overview is further substantiated by detailed study and observation in recent times in particular, the work done at the Vienna University of Technology (Institute of Microtechnique and Precision Engineering) and at the Austrian Center of Competence for Tribology. Specific examples from the recent literatures are described to exemplify the mechanisms of formation of various types of layers during high-temperature wear. Some thoughts on the future directions for research are also outlined.     

Tribological Behaviour of Polymeric Coatings: II. SCF‐Reinforced PEEK Nanocomposite Systems

This paper focuses on coatings based on poly(ether ether ketone) (PEEK) applied to metal substrates and their tribological investigation. Short carbon fibres (SCF), graphite, and 300 nm titanium dioxide (TiO₂) and zinc sulphide (ZnS) particles were used as filler materials for the PEEK. These filler materials and their combinations were found to have a significant influence on the tribological behaviour of the corresponding PEEK compounds. One of the compounds (PEEK6) was found, especially at higher temperatures and under higher normal loads, to be a good coating material showing superior tribological behaviour. For PEEK6, a specific wear rate and a coefficient of friction (COF) lower than those for the best commercially available PEEK compound (PEEK4) were measured. For specific test parameters, PEEK6 showed a COF of less than 0.1. The tribological results were also compared with those of a conventional sliding bearing material based on poly(vinylidene fluoride) (PVDF).     

Tribological behaviour of a PEEK polymer containing solid MoS2 lubricants

The addition of different concentrations (2–10 wt.%) of molybdenum disulfide (MoS₂) to a poly–ether–ether–ketone matrix has been studied in terms of the thermal, mechanical and tribological properties of the materials. The results of dry‐sliding tribological tests, differential scanning calorimetry and scanning electron microscope–energy‐dispersive X‐ray (EDS) analyses show that the concentration of MoS₂ influences the tribological, mechanical and thermal properties. With the highest concentration of MoS₂ (10 wt.%), the coefficient of friction was reduced by as much as 25%, while the maximum reduction in the wear rate was ~20%, which required 5 wt.% of MoS₂. The most important parameter when it comes to achieving an improved tribological behaviour was found to be the combination of a high hardness and a sufficient quantity of transfer film being formed. Copyright © 2015 John Wiley & Sons, Ltd.     

Tribological characteristics of silicon nitride at elevated temperatures

A sliding friction-and-wear test for silicon nitride (Si₃N₄) was conducted using a ball-on-disk specimen configuration. The material used in this study was HIPed silicon nitride. The tests were carried out from room temperature to 1000°C using self-mated silicon nitride couples in laboratory air. The worn surfaces were observed by SEM and the debris particles from the worn surfaces were analyzed for oxidation by XPS. The normal load was found to have a more significant influence on the friction coefficient of the silicon nitride than an elevated temperature. The specific wear rate was found to decrease along with the sliding distance. The specific wear rate at 29.4 N and 1000°C was 292 times larger than that at room temperature. The main wear mechanism from room temperature to 750°C was caused by brittle fracture, whereas from 750 to 1000°C the wear mechanism was mainly influenced by the oxidation of silicon nitride due to the increased temperature. The oxidation of silicon nitride at a high temperature was a significant factor in the wear increase.     

On the influence of test parameters on friction and wear of ceramics in oscillating sliding contacts

The tribological behaviour of different ceramics in contact with steel was studied for the case of oscillating sliding motion with a ball-on-disc apparatus. The influence of several test condition parameters was investigated by a systematic variation of the stroke, frequency, and normal load at room temperature in laboratory air at different levels of relative humidity. Each of the four parameters was varied in three stages. While the coefficient of friction was only mildly influenced by the operational variables, the coefficient of wear showed great variations and depended strongly on the humidity of the surrounding air. The effect of the operational variables and of the humidity on friction and wear varied for the different materials under investigation.     

Machinability study on composite (polyetheretherketone reinforced with 30% glass fibre–PEEK GF 30) using polycrystalline diamond (PCD) and cemented carbide (K20) tools

Polyetheretherketone (PEEK) is a relatively new technical thermoplastic material, which has excellent physical properties. By this reason exits a strong need to understand the issues associated with the machining of this thermoplastic. The major concern of this paper is the study of the cutting parameters (cutting velocity and feed rate) under power (Pc), specific cutting pressure (Ks), surface roughness (Ra) and International dimensional precision (IT) in PEEK reinforced with 30% of glass fibre (PEEK GF30). A plan of experiments, based on the methodology of Taguchi, was established considering turning with prefixed cutting parameters in the PEEK GF30 workpiece. The analysis of variance (ANOVA) was preformed to investigate the cutting characteristics of PEEK GF30 using a polycrystalline diamond (PCD) and a cemented carbide (K20) cutting tool.     

On the Effect of Counterface Material and Aqueous Environment on the Sliding Wear of Carbon Fibre Reinforced Polyetheretherketone (PEEK)

Carbon fibre reinforced Polyetheretherketone (PEEK/CF) was exposed to unidirectional sliding at a speed of 28 mm/s against various counterparts. Some of these tests were repeated in water. The bearing steel produced the worst results. In this case, the carbon fibre reinforcement even increased the wear compared to unreinforced PEEK. Most other counterparts led to wear rates almost a factor 100 lower. Chemically inert hard counterparts performed best. The lowest wear rates were found against DLC. An aqueous environment usually accelerated the wear process. Only in case of alumina and DLC counterparts, the water lubrication reduced the wear rate. The addition of graphite plus Polytetraflourethylene (PTFE) to PEEK/CF reduced the sensitivity to the operation conditions.     

Dry sliding friction and casing wear behavior of PCD reinforced WC matrix composites

The friction and casing wear properties of PCD reinforced WC matrix composites were investigated using a cylinder-on-ring wear-testing machine against N80 casing steel counterface under dry sliding conditions. The results indicate that the friction and casing wear rate of PCD reinforced WC matrix composites are the lowest among the materials. As the applied load and sliding speed steadily increase, the friction coefficients of PCD reinforced WC matrix composites decrease. In addition, the casing wear rates increase with increasing load, but decline with sliding velocity. The dominant wear mechanism of the PCD composite is the micro-cutting wear, accompanied by adhesive wear.     

45钢的摩擦磨损特性实验研究

采用自制的销盘式干滑动摩擦磨损试验机,研究了45钢配副的摩擦磨损特性.结果表明:材料的磨损率随着速度、载荷的增加而增大;摩擦系数随着速度、载荷的增加而减小.磨损机理主要为磨粒磨损和粘着磨损.     

Influence of counterface roughness on the friction and wear of polytetrafluorethylene- and polyacetal-based composites

The friction of various composites is generally little dependent upon the roughness. When the composites contain glass or carbon fibres, their wear rates are also little dependent upon the roughness. However, the wear rates of PTFE incorporating MoS₂, graphite or bronze and polyacetal incorporating PTFE increase rapidly as the roughness increases beyond a certain critical value characteristic of each of these composites. The roughness-dependency of the wear rate is markedly affected by the transfer during sliding.     

Friction and wear of carbon nanohorn-containing polyimide composites

Polyimide (PI)-based composites containing single-wall carbon nanohorn aggregate (NH) were fabricated using the spark plasma sintering (SPS) process. For comparison, composites with carbon nanotube (NT) and traditional graphite (Gr) were also fabricated. The NH was produced using CO₂ laser vaporization and a graphite target and the NT was produced by a chemical synthesis method. We evaluated the friction and wear properties of the PI-based composites with a reciprocating friction tester in air using an AISI 304 mating ball. NH drastically decreased the wear of PI-based composites; the specific wear rate of composite with NH of only 5 wt% was of the order of 10⁻⁸ mm³/Nm, which was two orders of magnitude less than that of PI alone. The wear reduction ability of NT seemed to be slightly inferior to that of NH, although it was considerably better than that of Gr. NH and NT lowered the friction of composites. The friction coefficient of composite with 10 wt% NH was less than 0.25, although it was slightly higher than that of composite with 10 wt% Gr. There was no clear difference in the friction reduction effect of NH and NT. The further addition of Gr to composites with NH or NT rather deteriorated the antiwear property of composites, although the friction coefficient was slightly reduced. The transferred materials existed on the friction surface of the mating ball, sliding against composites with three types of carbon filler. These transferred materials seemed to correlate with the low friction and wear properties of composites.     

Tribological behavior of polyetheretherketone, a thermotropic liquid crystalline polymer and in situ composites based on their blends under dry sliding conditions at elevated temperatures

The elevated temperature dry sliding friction and wear behavior of injection molded polyetheretherketone (PEEK), a thermotropic liquid crystalline polymer (TLCP), and in situ composites based on PEEK-TLCP blends were investigated. Results from sliding tests conducted on a pin-on-disk tribometer at selected temperatures within the range from 20 to 250°C are reported. Friction and wear mechanisms are related to the microstructure and phase behavior of the material systems investigated. TLCP concentration and thermally activated molecular relaxation processes are related to the mechanical properties and tribological performance of the PEEK-HX1000 blends. The potential of TLCP in situ reinforcement as a route towards the development of performance thermoplastic-based tribomaterials for high temperature use is discussed.