Wear 247 (2001) 208–213

On the SEM features of glass–epoxy composite system

subjected to dry sliding wear
Kishore a,∗ , P. Sampathkumaran b , S. Seetharamu b , A. Murali b , R.K. Kumar b
aDepartment of Metallurgy, Indian Institute of Science, Bangalore-560012, India
b Materials Technology Division, Central Power Research Institute, Bangalore-560094, India
Received 2 October 1999; accepted 29 September 2000

Abstract
The scanning electron microscope (SEM) features of glass fiber–epoxy composites subjected to sliding wear for distances ranging from
500 m to 6 km are recorded in this work. The results have shown that there is an existence of noticeable features on the worn surfaces.
Thus for the longer run case interface separation is noticed, while for shorter runs matrix debris formation and occasional glass fiber
fragmentation are seen. The work also highlights the effect of load and sliding velocity on the wear loss pattern. © 2001 Published by
Elsevier Science B.V.
Keywords: Glass–epoxy; Pin-on-disc; Dry sliding wear; SEM observations

1. Introduction sliding wear of glass–epoxy (G–E) has been looked into.

The study of wear of polymers in general and polymer
based systems in particular is finding increasing citations in
literature [1] due to the availability of wider choice of mate-
rials, ease of manufacturing, good strength and light weight.
An area where their use has been found to be very effec-
tive is the situation involving sliding contact wear [2]. The
polymer based materials are preferred in recent years over
metal based counterparts in view of their low coefficient
of friction [3] and ability to sustain loads. This has given
an impetus to industrial production of the materials, as for
instance in the production of bearing components used in
automobile industries [4] such as gears, cams, wheels, etc.
The introduction of fibers as reinforcing agents in epoxy
[5] based polymer materials widen the scope for structural
application in view of their prossessing useful properties
[6,7] like tensile strength in the range 240–280 MPa, flex-
ural modulus in the range 16–20 GPa, impact toughness
(Izod) in the range 290–370 J/m, interlaminar shear strength
in the range 25–50 MPa in addition to light weight (den-
sity 2000–2400 kg/m3 ). However, the deployment of these
as components for use in actual service requires good under-
standing of the processing related structure and its influence
on wear. Keeping this aspect in mind, the response to dry
∗ Corresponding author. Tel.: 91-80-3344411/ext. 2683;
fax: 91-80-3341683.
E-mail address: balkis@metalrg.iisc.ernet.in (Kishore).
The emphasis is to study the sliding wear behavior of the
cross-section of glass fiber reinforced epoxy resin compos-
ites and record the resulting surface features using a scan-
ning electron microscope (SEM) [8] for structure-property
correlation, since the literature on this is scanty.
2. Materials and methods
2.1. Fabrication of glass fibrous composite laminates and
test specimens
The G–E material used in this investigation was made
from the hand lay-up technique using a compression mould-
ing process [5,7]. The procedure consisted of placing the
glass fibers with epoxy compatible finish on a substrate ma-
terial which had a release coat applied on it. Weighed quan-
tities of room temperature curing epoxy resin (LY 556, sup-
plied by Hindustan Ciba-Geigy Ltd., Mumbai) plus hard-
ener mix was taken and smeared over the glass fabric. On
this, another layer of the glass fabric was laid and the pro-
cess continued. The whole lay up was covered with a mat
finished fabric over which was placed a steel plate with the
necessary release coat applied on it. The lay up assembly
was pressed in a press. The excess resin was allowed to
squeeze out. The laminate was cured at ambient conditions
for a period of about 24 h. The thickness of the laminate was
about 3 mm, obtained by using spacers. The cured material
was cut using a diamond tipped cutter to yield wear test

0043-1648/01/$ – see front matter © 2001 Published by Elsevier Science B.V.

PII: S 0 0 4 3 - 1 6 4 8 ( 0 0 ) 0 0 5 3 7 - 8
 Kishore et al. / Wear 247 (2001) 208–213
coupons of size 6 mm × 6 mm. In the present investigation,
as the laminates were made by hand lay-up technique, the
mechanical properties are expected to be lower compared to
the values mentioned earlier.
2.2. Test set up and wear runs
The test coupon was then inserted and glued in the
thickness direction using an adhesive to pins of size 6 mm
diameter × 25 mm length and having groove in one end of
the pin to rigidly hold the sample (Fig. 1a). This mounting
arrangement was different from the earlier experimental
work [8,9], wherein the flat portion of the alternate lay-up
sequence of glass and epoxy, comes in contact with the
counter surface. In the present case, the cross section of
glass–epoxy sample makes contact with the counter sur-
face as detailed in Fig. 1b. The counter surface used in the
present work is an alloy steel disc of hardness 62 HRC and
having surface roughness of Ra = 10 ␮m. The initial weight
of such test coupon/pin assembly was recorded accurately
using a digital electronic balance after cleaning. After fix-
ing both the disc and the sample pin in their respective
positions, the normal load to the pin was applied through
a pivoted loading lever with a string and pan assembly [9].
The required loads were applied by placing known dead
weights on the pan. The test was conducted by selecting
the test duration, load and velocity. At the end of the test,
the sample was again weighed in the same digital balance
after cleaning using an air blower.
2.3. Test parameters
The values of load, velocity and sliding distance employed
in this work, varied from 20–60 N, 2–4 m/s and 0.5–6 km,
Fig. 1. (a) Schematic showing the mounting of the test piece in the pin
holder assembly and (b) inset of the G–E test sample showing glass fabric
arrangement.
209
Fig. 2. A graph showing weight loss vs. load for a sample subjected to
3 m/s sliding velocity and 4 km sliding distance.
respectively. The weight changes in a sample was measured
by recording the initial and final weights. This procedure
of recording of weights was followed for at least four test
samples for a fixed sliding velocity, load and distance run.
The scatter band has been provided for each of the velocity
and load employed in this work. The repeatability of test
wear runs were established by determining the coefficient of
variation [10] which was well with in the acceptable limit of
10%. For SEM studies, the wear test coupons subjected to
select combinations of load and sliding speeds were sputter
coated with a thin conducting layer of gold.
3. Results and discussion
The weight loss values recorded are presented in Figs. 2
and 3. Fig. 2 shows the effect of load in the range 20–60 N
on the weight loss of test coupon for a total sliding distance
of 4 km at 3 m/s sliding velocity. The weight changes with
respect to sliding velocities in the range 2–4 m/s at 40 N are
depicted in Fig. 3. In both the cases (Figs. 2 and 3) the trend
for the weight loss is to show an increase with load and ve-
locity, respectively. These findings are further supplemented
Fig. 3. A plot describing weight loss vs. sliding velocity for a sample at
40 N load.
210 Kishore et al. / Wear 247 (2001) 208–213

Fig. 4. SEM photograph showing the features of worn surface at 500 m sliding distance, 40 N and 3 m/s.

by the surface features as seen in SEM photomicrographs
taken at the central region of the worn surfaces.
Fig. 4 records the SEM features of the worn surfaces for
the 0.5 km at constant values of load (40 N) and velocity
(3 m/s). The spread of the matrix and faint cracks, with some
debris (marked ‘P’) are noticed. However, a detailed exam-
ination of the 1 km run sample showed (Fig. 5) a tendency
for the exposed longitudinal fibers to fragment thus bringing
out the effect of distance on the wear surface features. The
matrix (Fig. 5) retains less of the wide spread, continuous
mass-like features seen in Fig. 4. Further the matrix debris
appear (Fig. 5) in increasing amount and the discontinuous
glass fibers that are fragmented are distributed at random
orientations (for example, at regions marked ‘F’).

Fig. 5. Surface features showing the SEM observation for 1 km run at 40 N and 3 m/s.
 Kishore et al. / Wear 247 (2001) 208–213 211

Fig. 6. SEM surface features for 2 km run at 40 N, 3 m/s showing debris on the sample surface.

Increasing amounts of debris are noticed in longer run
sample (2 km, Fig. 6). The spread of the debris partly
masks the fibers at regions marked ‘K’ on top center of
the photograph. Fig. 7 features situation prevailing for still
longer run case (4 km). Both transverse and longitudinal
fibers can be noticed. Also visible are a few broken fibers
(marked by arrows). The test sample subjected to still
longer sliding distance of 6 km (40 N, 3 m/s) is depicted
in Fig. 8, wherein in addition to debris formation and bro-
ken fibers, crater formation due to combined factors like
the long wearing-in process coupled with widening of an
existing defect (for instance a void) and its emergence at
the surface leading to hollow appearance. Consequently,
in this photomicrograph, the subsurface (underneath) layer

Fig. 7. SEM surface features depicting fragmentation of fibers with debris on the surface of sample at 4 km sliding distance, 40 N and 3 m/s.
212 Kishore et al. / Wear 247 (2001) 208–213

Fig. 8. SEM picture for 6 km run sample at 40 N, 3 m/s showing a crater-like feature.

clearly exposed due to the parting off of the top layer is
noticed. The matrix debris seen in the photomicrograph
could be an additional factor in furthering the wear process
[11].
The effect of changing the load to either 20 or 60 N at
sliding distance (4 km) and velocity (3 m/s) is brought out in
Figs. 9 and 10, respectively. Compared to Fig. 7, the surface
features depicts (Fig. 9) less of fiber exposure thus highlight-
ing the effect of decreasing the applied load from 40 to 20 N.
On the other hand, increasing the load to 60 N (Fig. 10) has
the effect of showing the features resembling interface sepa-
ration (across the top region of the photograph). Besides the
matrix has a coloration change probably effected by the fric-
tional heat developed. Summarizing, the photomicrographs
(Figs. 7, 9 and 10) presented earlier corroborate the general
trend seen in weight changes in that the matrix debris for-
mation and fragmentation of fibers are larger when the value
of the applied load is higher.

Fig. 9. SEM picture depicting worn surface features for 4 km run sample at a load of 20 N and velocity of 3 m/s.
 Kishore et al. / Wear 247 (2001) 208–213
Fig. 10. SEM photograph showing features at 60 N, 3 m/s, for 4 km distance run sample.
4. Conclusions
The worn surface features reflect characteristically the
effect of total distance run during slide wear experiments.
Thus small distances run sample show a varying trend
for the matrix from continuous mass-like feature to small
amount of debris formation. The longest run sample, on
the other hand, display interface separation features besides
debris getting detached. This situation leads to an increased
wear and a general coloration change on the surface. The
samples subjected to wear for the sliding distances in the
range 0.5 m–6 km show features like increase in matrix
debris formation, fibers breakage and exposure of both
longitudinal and transverse fibers due to the wear of the
matrix.
Acknowledgements
The authors would like to acknowledge the assistance of
Mr. D. Mollaiah for the help rendered and the Chairman
of the Department of Metallurgy (Prof. D.H. Sastry) for
the keen interest shown in the work. The authors thank the
CPRI management for the permission extended to publish
this paper. The authors also thank Mr. S. Vynatheya and Mr.
M.R. Mohan for the help rendered in taking SEM pictures
and in conducting experiments, respectively.
213
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