Wear 262 (2007) 727–735

Influence of weave of carbon fabric on low amplitude oscillating wear

performance of Polyetherimide composites
Rekha Rattan, J. Bijwe ∗ , M. Fahim
Industrial Tribology Machine Dynamics and Maintenance Engineering Centre (ITMMEC), Indian Institute of Technology Delhi, Hauz Khas,
New Delhi 110016, India
Received 11 March 2006; received in revised form 24 July 2006; accepted 3 August 2006
Available online 20 September 2006

Abstract
Three composites were fabricated based on Polyetherimide (PEI) matrix and carbon fabric (CF) (55 vol.%) of different weaves, viz. plain, twill
and satin (4H) by impregnation technique. These composites were evaluated for various mechanical properties and tribological performance in
low amplitude oscillating wear (LAOW)/fretting wear mode. It was observed that CF reinforcement led to a significant enhancement in all strength
and modulus properties of PEI except elongation to break (e). Twill weave proved to be the most effective followed by satin and plain weave in
almost all the properties. The LAOW mode evaluation under various loads revealed that the wear performance order was exactly opposite to the
above trend. Overall, plain weave composite was the best performer followed by twill and satin. Various wear mechanisms, such as fiber-matrix
debonding due to repetitive reciprocating shearing stresses, micro-cracking, micro-cutting and pulverization of fibers followed by removal of debris
from the contact zone were operative during such wear situation. Amongst these processes, generation of fiber debris, their temporary retention in
fabric weaves and subsequent removal from the crater played a key role in overall wear performance. The ability of plain weave to hold back the
debris was maximum that resulted in lowest wear while satin weave had the minimum retention ability that led to the highest wear. The proposed
wear mechanisms were supported by SEM studies.
© 2006 Published by Elsevier B.V.

Keywords: Low amplitude oscillating wear; Fretting wear; Carbon fabric reinforced composites; Fabric-weave tribology

1. Introduction (CFRP) have immense potential in numerous applications in

Wear of components under oscillatory relative motion (either
linear or torsional) of small amplitude of displacement is termed
as low amplitude oscillating wear (LAOW) or fretting wear. Such
oscillatory motion can be intentional or unintentional. Rolling
bearings used for small oscillatory movement, bearing’s outer
ring and housing, wire ropes, electrical switchgears, multilayer
leaf springs, palliatives, spline couplings, flanges, seals, riveted
and pinned joints, etc. may suffer from such type of wear dam-
age [1–4]. Reinforced polymers and composites are frequently
used to make such components [5–7]. In spite of this fact, not
much is available on fretting wear behavior of these materials
compared to vast literature available for metals and alloys [2].
Among reinforced polymers, carbon fiber reinforced polymers
∗ Corresponding author. Tel.: +91 11 26591280; fax: +91 11 26591280.
E-mail addresses: jbijwe@gmail.com, jbijwe@hotmail.com (J. Bijwe).
which fretting wear situations may arise. CFRP ropes, for exam-
ple, if used in the place of steel rope for the construction of light
weight suspension bridge, low amplitude oscillatory wear would
occur between the retaining parts and the CFRP ropes [7]. CFRP
components are used in aeronautical and space applications in
large scale [8] and are prone to similar damages in some situa-
tions, which can be fatal and lead to accidents. It was a technical
snag that had forced the pilot for an emergency water landing to
avoid an accident. Later, the inspection of aircraft parts revealed
that fitting beams had undergone fretting wear and cracking that
were responsible for the mishap [9].
Among fabric reinforced or bi-directional (BD) composites,
as they are popularly called, CFRPs are being increasingly used
in aircraft industry as structural material because of very high
specific strength and modulus. However, hardly any literature
is available on the fretting wear behavior of such BD compos-
ites [10,11]. In our earlier work, significant benefits endowed by
inclusion of carbon fabric (69 vol.%) in PEI matrix were reported

0043-1648/$ – see front matter © 2006 Published by Elsevier B.V.

doi:10.1016/j.wear.2006.08.005
728 R. Rattan et al. / Wear 262 (2007) 727–735

Table 1b
Properties of three weaves of carbon fabric measured in the laboratory
Carbon fabric Plain Twill Satin (4H)

Density (g/cm3 ) 1.85 1.85 1.85

Area (g/cm2 ) 196 198 193
Towa 3K 3K 3K
Tex 20 22 19
Denier 185 198 171
Crimp (%) 0.64 0.70 0.30
Fig. 1. Schematic showing different weave patterns (i) plain (one weft over one
Count 28 26 31
warp), (ii) twill (two warp over two weft) and (iii) satin (4H) (one warp over
Warp (in.) 12 16 14
three weft).
Weft (in.) 12 16 14
Thickness (cm) 0.34 0.34 0.36
[10]. In a subsequent work, a series of CF reinforced BD com- Bending length (cm) 7.2 5.9 5.0
posites containing various amounts of fabric was developed and Tensile strength (kg/cm2 ) 3 1.47 1.2
evaluated to investigate optimum amount of CF in PEI for best Elongation (%) 1.25 1.85 1.52
combination of tribo-performance and strength [11]. Though a Supplier’s data.
weave of fabric is very important in controlling strength prop-
erties of the composites, no paper is reported on the influence were taken out carefully to avoid the misalignment in weave and
of weave of CF in any matrix in LAOW mode. Interestingly, a dried in oven for 2 h at 100 ◦ C in a stretched condition. These 20
little is reported in case of glass fabric reinforced PEI compos- prepregs were used to attain the desired thickness in the range
ites in abrasive wear mode [12], and in thermoset composites in of 3–3.5 mm and were stacked in the mould carefully to avoid
adhesive wear mode [13]. Hence, it was proposed to investigate misalignment. PTFE coated glass fabric was placed on the top
influence of three weaves of CF in PEI on strength properties and bottom of the stacked prepregs. During compression mold-
and LAOW performance. The results are presented in subse- ing, the mould was heated to attain the temperature in the range
quent sections. of 385–390 ◦ C within 2 h. The prepregs were then compression
molded at this temperature at an applied pressure of 7.35 MPa.
2. Experimental During the total compression time of 20 min at high temper-
ature four intermittent breathings (each of 2 s) were applied to
2.1. Fabrication of composites expel any residual solvent. The composites were allowed to cool
under ambient conditions and applied pressure 7.35 MPa. The
GE plastics USA supplied the PEI material (ULTEM 1000) as test specimens were cut from the composites with the help of
granules. The carbon fabric used as reinforcement was procured diamond cutter as per required standards for mechanical and
from Fiber Glast Ltd. USA. Carbon fabrics of three different tribological testing.
weaves, viz. plain weave (P), twill weave (T) and satin weave-4
harness (S) as shown in Fig. 1 were selected. The properties of 2.2. Characterization of the composites
these fabrics were studied in the laboratory and are compiled in
Table 1. The three composites were developed keeping the fabric The plain, twill and satin weave reinforced composites were
concentration constant (55 vol.% or 65 wt.%) using impregna- designated as IP55 , IT55 and IS55 , respectively. The three com-
tion technique (I). The plies (280 mm × 260 mm) were cut from posites fabricated for the present study were characterized for
the carbon fabric roll and the open strands from all the four sides physical properties and composition using Soxhlett apparatus
were sealed with a PTFE coated glass fabric tape to avoid the and Dichloromethane as a solvent. The extraction temperature
fiber misalignment. These plies were immersed individually in and time were 40 ◦ C and 36 h, respectively. Composites were
separate containers filled with viscous solution of PEI (prepared also evaluated for various mechanical properties as per ASTM
with Dichloromethane) for 12 h. The containers were properly standards. The mechanical properties of these composites are
sealed to avoid evaporation of solvent, which was required for shown in Table 2. (Properties of PEI were provided by the sup-
adequate wetting of fiber strands with the PEI solution. The plies plier).

Table 1a 2.3. Oscillating wear studies

Characteristic properties of various weaves of fabric [16]
Property Plain Twill Satin The studies were done on SRV Optimol Tester [10], in which
a chromium steel ball of diameter 10 mm was oscillated against
Good stability Good Acceptable Poor
Good drape Poor Good Excellent a polymer composite plate (10 mm × 10 mm × 3–4 mm). The
Low porosity Acceptable Good Excellent direction of fabric and fibers with respect to oscillation is shown
Smoothness Poor Acceptable Excellent in Fig. 2. The operating parameters were as follows.
Balance Good Good Poor
Symmetrical Excellent Acceptable Very poor
Low crimp Poor Acceptable Excellent
Load: 100, 150, 200, 250 and 300 N
Stroke length (full oscillation width)—1 mm;
 R. Rattan et al. / Wear 262 (2007) 727–735 729

Table 2 The specific wear rate was calculated using the equation:
Details of the composition and properties of fabricated composites
V
Composites PEI* IP55 IT55 IS55 K0 =
2AνtFN
Density (g/cm3 ) ASTM D 1.27 1.55 1.53 1.54
792 where Ko is the specific wear rate in m3 /N m, V the wear
Contents of fabric (%, v/w) – 55/65 55/65 55/65 volume (m3 ) and FN the applied normal load (N). 2Aνt (where
Tensile strength (MPa) 105 535 888 575 A is the full oscillation width (m), ν the frequency (Hz) and t is
ASTM 638
Tensile modulus (GPa) 03 73 106 76
the experimental duration in (s)) indicates total sliding distance.
ASTM 638
Elongation at break (%) 60 0.54 0.08 0.32 3. Results and discussion
ASTM 638
Toughness (MPa) ASTM 638 – 3.8 2.2 2.8
Flexural strength (MPa) 150 589 951 832
As seen from Table 2, the strength performance of the com-
ASTM 790 posites was in the order; IT55 > IS55 > IP55 ≫ PEI for all prop-
Flexural modulus (MPa) 3.3 40 54 46 erties except toughness and elongation, where the order was
ASTM 790 reverse.
Inter laminar shear strength – 49 66 63 The friction and wear performance of the selected composites
(ILSS) (MPa) ASTM 2344
under various loads is shown in Fig. 3. Possible wear mecha-
* Properties of PEI as per supplier’s data. nisms are shown in Fig. 4 and SEM micrographs of worn pin
surfaces are shown in Figs. 5–7.
Fig. 3a shows the variation of friction coefficient (µ) with
increasing loads for all the three composites. The µ decreased
with increasing loads and was in the range of 0.3–0.4. For

Fig. 2. Schematic showing ball on plate (composite) configuration.

Test duration—2 h;
Oscillating frequency—50 Hz,
Temperature—25 ◦ C.

The load was increased on the ball fretting against a compos-

ite plate after each experiment in the step of 50 N till limiting
load1 reached.

1 In the case of LAOW all selected parameters including amplitude are set

before the experiment starts. Once the oscillation starts, generally amplitude
falls below the set value and it is reset with the control panel. However, when
load is very large and shearing forces are high, amplitude cannot be maintained
even after applying maximum range provided in the control unit. This shows that
the limiting load has reached. Sometimes amplitude reduces because of trapping
of large particles of metal or polymer and falls to a low value for a short time. It
regains once the particle either is thrown off or gets “wear thinned”. However, if
the value falls below 80% of original value for a long time even after applying full
possible force through control unit, it is realized that the material has reached
the “failure limit” and cannot withstand the selected load. The experiment is Fig. 3. (a) Coefficient of friction and (b) specific wear rate (Ko ) as a function of
abandoned and lower load is selected for next experiment. load.
730 R. Rattan et al. / Wear 262 (2007) 727–735

Fig. 4. (a) Cross-section view of unit cell of (a) plain, (b) twill and (c) satin weave fabric; L1, L2 and L3 denote distance between mid-point of contact and the point
where the crimp starts. (b) Schematic of the events of most probable sequence during fretting wear of plain weave fabric reinforced composite. A—Situation prior
to fretting: (a) top view of weave and direction of fretting, (b) cross-section of unit cell and (c) contact configuration. B—Just initiation of fretting: (a) wear debris
generation due to fiber damage, (b) larger sized fiber/matrix debris in contact zone and (c) sub-surface damage. C—Fretting continued: (a) initiation of travel of
debris towards pockets, (b) retention of debris in pockets and (c) thick layer of entrapped fibrous and polymeric debris leading to third body interphase. D—Fretting
continued: (a) wear thinned fibrous debris accumulation in pockets, (b and c) shearing of debris. E—Fretting in advanced stage: (a) pocket saturated with fibrous
debris offering more wear resistance by further wear thinning, (b and c) accumulation beneath the crimp leading to saturation; excess debris escape the contact zone
leading to measurable wear.
 R. Rattan et al. / Wear 262 (2007) 727–735 731

Fig. 5. Scanning electron micrographs (×15) of IP55 worn under (a) 100 N and (b) 250 N; and IT55 worn under (c) 100 N and (d) 250 N loads, respectively.

almost all loads plain weave composite showed the lowest µ resistance which is calculated as per following equation
followed by twill and satin composites. µ of PEI, however, was
Wear resistance of composite
always high 0.41 and was independent of load as reported in RWR =
our earlier paper [10]. Thus, inclusion of CF reduced µ by Wear resistance of PEI
approximately 25%, which was due to the lubricating action Since limiting load for PEI was 200 N, the data for comparison
of CF. A lower µ at higher loads was attributed to the lubric- was selected accordingly. As seen from Table 3, a significant
ity provided by the fine CF powder formed due to crushing increase in wear performance due to CF inclusion can be seen.
and grinding of fiber pieces that accumulated at the contact Approximately 8.4 times increase in performance was showed
zone. by IP55 . Overall, the improvement was in the range 4–8.4 for
The specific wear rate (Ko ) plotted as a function of load in various composites evaluated under different loads.
Fig. 3b indicates that Ko increased with increase in load for It is a well known fact that wear behavior in fretting wear
all the composites, which is a general trend observed in the mode is very different than that in sliding wear mode. It is the
case of fiber-reinforced composites [3,10,11]. The limiting load reciprocating motion in the former, which makes the major dif-
(and hence range of utility of the composite in harsh operating ference in wear mechanisms in two modes. Wear processes in
conditions) of plain and satin weave composites was 300 N while such dry frictional contacts are considered as a succession of
that of twill weave was slightly lower (250 N). IP55 was the individual events involving particle detachment from the con-
best performer from tribological point of view, but poorest from tacting bodies i.e., debris formation, its trapping and shearing in
strength point of view. Composite IS55 showed second best wear the contact zone and subsequent escape from the same. Among
performance under only moderate loads (100–150 N). At higher
loads, however it showed highest wear rate. Its friction behavior
was also poorest in all conditions. Table 3
Twill weave composite IT55 on the other hand was second Relative wear resistance of composites at various loads (RWR = Ko of
best in both wear as well as friction performance under higher composite/Ko of PEI)
loads. Ko was least dependent on load as compared to other Material Relative wear resistance (RWR)
composites.
50 N 150 N 200 N
Overall order of friction and wear performance of compos-
ites was: IP55 > IT55 > IS55 . The strength and modulus of the PEI 1 1 1
composites, however, did not follow the same order. The wear IP55 6.55 8.38 7.28
IT55 4.08 6.00 6.08
performance of the composites was compared with that of Neat
IS55 7.03 6.55 5.17
PEI (data taken from Ref. [10]) in the form of relative wear
732 R. Rattan et al. / Wear 262 (2007) 727–735

Fig. 6. SEM (×500) of composites worn under 100 N (WR -IS55 ∼ = IP55 ≫ IT55 ); (a) long fibers, longitudinally wear thinned and embedded in the matrix, (b) back-
transfer of matrix, (c) magnified view (×1500) of fiber damage with micro-cracking, (d) shows worn surface of IP55 and back-transfer of matrix in the form of
patches and (e) shows the worn surface of the composite IT55 and debris embedded in the matrix.

these, the escape of wear debris is minimal if the slip amplitude
is very small. In the case of engineering polymers, the effect of
contact zone kinematics on the wear is significant when the third
body formation leads to abrasion or the transfer of polymer films
to the counterface as well. The wear process is also affected by
the formation of ‘loose’ or ‘tight’ compacts from the debris and
its subsequent rheological behavior [3]. Thus, the wear behav-
ior of materials is quite different from that in other wear modes
and cannot be predicted a priori. There are a number of cases
reported where inclusion of solid lubricants or fibers or both did
not render the expected benefits. The performance on the other
hand deteriorated [14,15].
The wear resistance (WR ) (inverse of wear rate, Ko ), was
highest for plain weave composite followed by twill and satin.
This was not related to any strength properties of these com-
posites, rather it was mainly because of the difference in wear
mechanisms. The wear process involves various mechanisms
such as fiber-matrix debonding followed by fiber breakage as a
result of micro-cracking, micro-cutting and micro-pulverization
due to reciprocating shearing stresses. The wear also depends
on the amount of fiber debris produced and its escape from
the contact zone. Amongst all weaves, plain weave is the most
tight (least flexible) followed by twill and satin. This would
result maximum fiber damage to the plain weave composite.
However, the same weave is also responsible for the retention
of fiber debris in the contact zone. Thus, fretting wear of fabric-
reinforced composites is a complex phenomenon that comprises
multiple mechanisms which are operative successively and then
simultaneously. Fig. 4a shows the unit cells of three weaves.
It highlights the variation in distance between mid-point of
contact and the point of starting of crimp. This distance has
critical impact on wear mechanisms. Higher the distance,
 R. Rattan et al. / Wear 262 (2007) 727–735 733

Fig. 7. SEM of IP55 worn under 250 N showing (a) weave of fabric (marked as 1), (b) magnified view (×1000) fiber debris embedded in the matrix, (c) retention of
fiber debris in the weave pockets marked as 1 and fiber-matrix debonding marked as 2, (d) magnified view (×1000) for IT55 showing cavities (marked as 1), fiber
piece escaped from cavity (marked as 2), fiber-matrix debonding (marked as 3) and (e) worn surface of (×500) IS55 showing long fibers and cavities.

lower is the probability of fiber debris reaching to crimp and
getting entrapped. If entrapped, they will cause negative wear.
The distance being largest in satin weave, the probability of
entrapment was lowest. This was one of the reasons for highest
wear of satin weave composite. The same distance was lowest
for plain weave composite and hence offered highest possibility
of retention of debris beneath the crimp leading to lowest
wear.
Fig. 4b is self-explanatory and depicts fretting mechanisms
of plain weave composite. Various events that take place sequen-
tially are collected in Table 4. The impact (positive or negative)
on weight loss of a composite is also indicated in the same table.
The mechanisms suggested in Table 4 and Fig. 4b are supported
by SEM studies as discussed in the subsequent section.
In the case of satin weave composite, similar mechanisms
(Fig. 4a) take place except for the difference in the degree of
extent. The satin weave is the least compact (Table 1a) amongst
three followed by twill and plain. Hence, the tendency of reten-
tion of debris beneath the crimp and pockets is minimum for satin
and maximum for plain weave composite, a fact that supports the
highest and lowest wear rates for the former and latter. Thus, the
initial fiber breakage process though is maximum in plain weave
composite, the further damage processes are minimal and reten-
tion processes are maximum. Satin weave being loose, on other
hand, fiber breakage is minimal because of highest length of
fiber, and hence maximum flexibility, between crossover points.
Thus, plain weave composite showed highest WR , despite maxi-
mum fiber pulverization, mainly because of its highest tendency
of retention of wear debris in the pockets and beneath the crimp
point. The maximum tightness of the plain weave and maximum
crimp points (Table 1a) were responsible for retention of debris
leading to lowest wear of this composite.
734 R. Rattan et al. / Wear 262 (2007) 727–735

Table 4
Possible wear mechanisms and extent of their contribution towards weight loss/wear rate
Parameters and events during fretting of a ball on a composite plate Effect on wear rate Extent of Effect
(WR , wear resistance)
Plain Twill Satin

1 Wear thinning of fibers parallel to the direction of slip; higher the − Minimum Moderate Maximum
better for WR . Longer the fibers more the wear thinning
2 Breakage of fibers due to micro-cracking and micro-cutting. Lesser, + Maximum Moderate Minimum
the better for WR
Generation of wear debris. Lesser, the better for WR +
3 Length of the fibers between crimp points and associated flexibility. + Maximum Moderate Minimum
Higher, the better for WR ; LS > LT > LP
4 Wear debris escape from the contact zone. Lesser the probability, + Minimum Moderate Maximum
the better for WR
5 Retention of debris trapped in the pockets of the weave. Higher, the − Maximum Moderate Minimum
better for WR
6 Formation of intermediate layer due to shearing of debris. Thicker − Maximum Moderate Minimum
the better for WR
7 Embedment of debris retained in the zone followed by wear − Maximum Moderate Minimum
thinning; Higher, the better for WR
8 Tightness of weave responsible for efficient entrapment of debris; − Maximum Moderate Minimum
tighter, the better for WR
9 Quick entrapment of debris beneath the length of crimp (crossover − Maximum Moderate Minimum
points); Higher, the better for WR

(+) Sign indicates contribution to weight loss; (−) sign indicates protection from wearing. For plain weave composites events 1–3 are unfavorable for increasing
WR while factors 4–9 are favorable. Resultant of these led to highest WR . Exactly reverse is true for satin weave composite. However, extent of contribution of these
mechanisms depends on operating parameters, especially applied load.

3.1. SEM studies
Scanning electron micrographs of worn composite surfaces
in the order of increasing wear rate are shown in Figs. 5–7. Fig. 5
shows the general appearance of craters and influence of load
on their size at lower magnification (×15). Micrographs 5a and
b show the craters for composite IP55 worn under 100 and 250 N
loads, respectively, while 5c and d are for composite IT55 worn
under 100 and 250 N loads, respectively. The size of the craters
has increased with load because of higher wear. Micrographs
6 and 7 show surfaces worn under lower (100 N) and higher
(250 N) loads, respectively. At 100 N, wear performance of
composites was in the order IP55 ≈ IS55 ≫ IT55 . Micrographs
6a–c show worn surface of IS55 . As seen in micrograph
6a, the weave being satin, long fibers, longitudinally wear
thinned and well embedded in the matrix appear on the surface
(event 1 described in Table 4). A little back-transfer of resin
(marked 1) is also appearing on the surface. Micrograph 6b
shows another location where various stages of fiber damage
(marked 1) and back-transfer of the matrix (marked as 2) can be
clearly seen. Few fibers are completely broken leaving behind
cavities (marked as 3). Enhanced fiber-matrix debonding
responsible for higher wear can also be seen (marked as 4).
Micrograph 6c shows finer features of fiber damage which
initiates with micro-cracking, followed by micro-cutting,
pulverization in the form of powder and subsequent removal
from the surface leaving behind cavities as seen in the
micrograph.
Micrograph 6d shows worn surface of IP55 . Surface, overall is
very smooth supporting lowest wear rate (similar to IS55 ) of this
composite. Most of the area was covered with back-transferred
matrix in the form of patches (marked as 1). The pulverized
debris of fibers is efficiently embedded in these patches (this
was one of the very critical factors i.e., retention of debris-
responsible for highest WR ). The dark boundaries of patches
give the false notion of being cracks. Carbon fibers longitu-
dinally wear thinned can also be seen. The length of such
fibers, however, is shorter than that observed in IS55 . These
broken fibers and pulverized debris are very well embedded
in the matrix and no evidence of fiber-matrix debonding could
be seen.
Micrograph 6e shows the worn surface of the composite IT55 ,
that exhibited the highest wear rate at 100 N. The wear damage
to the fibers is severe as compared to mild wear observed in
earlier micrograph (6d). Another difference was in the nature
of back-transferred layer of matrix (marked as 1). The extent
of debris embedded in the matrix and hence retention of wear
debris was less, which could be the cause of highest wear rate
of the composite.
Micrographs of composites worn under higher load
(250 N) are shown in Fig. 7. At this load order of WR was
IP55 > IT55 > IS55 . The features in micrographs 7a–c support
the highest WR of IP55 . Though the fiber damage is severe
(events 2, 3 in Table 4) hardly any cavities are seen (events 6, 7
in Table 4). This indicated the high capability of this composite
for wear debris retention, which was suggested as main reason
of highest WR of the composite. The micrograph also shows the
weave of fabric (marked as 1) (event 5 in Table 4). Micrograph
7b shows magnified view (×1000) of the surface confirming
well-embedded fiber debris in the matrix in various orientations
that provided temporary wear protection. Micrograph 7c shows
another location of the same composite surface (×1000) with
 R. Rattan et al. / Wear 262 (2007) 727–735
evidence of retention of fiber debris in the weave pockets
(marked as 1) (event 5 in Table 4). A location marked as 2
shows some evidence of fiber-matrix debonding because of
higher frictional heat as a consequence of higher load.
Micrograph 7d shows the magnified view (×1000) of worn
surface of IT55 . The fiber damage though is less, the extent of
removal of debris leaving behind cavities (marked as 1) is very
high, which was a major cause of higher wear. The fiber piece
(marked as 2) that was uplifted from the cavity is seen lying on
the surface ready to be thrown out of the contact zone. Some
evidence of fiber-matrix debonding because of higher frictional
heat as a consequence of higher load can also be seen (marked
as 3).
Micrograph 7e (×500) shows the worn surface of IS55 , which
has shown highest wear. The long fibers fractured at various
places because of high load can be seen. The surface shows
maximum damage as seen in the left portion of the micrograph.
A number of cavities formed due to fiber debris removal and
mostly responsible for highest wear of this composite can also
be seen.
4. Conclusions
Based on the fretting wear studies carried out on the selected
composites of Polyetherimide reinforced with carbon fabric of
three different weave patterns, it was observed that plain weave
reinforced composite (IP55 ) provided maximum resistance to
fretting wear and lowest coefficient of friction followed by twill
(IT55 ) and satin weave composite (IS55 ) in severe operating con-
ditions. Inclusion of CF improved WR of PEI significantly (4–8.4
times depending on load and weave of fabric). µ on other hand
was benefited marginally (∼25%). With increasing loads, wear
rate increased and µ decreased gradually.
The difference in WR of the three composites was attributed
to the difference in the capability of retention of pulverized
fiber debris in the pockets of the weave and below the crimp
points as supported by SEM. Plain weave was the most effec-
tive in retaining debris and provided highest wear protection
while satin was the least effective in this aspect leading to poor-
est performance. Proposed wear mechanisms were supported
by SEM.
735
Acknowledgement
Authors are grateful to the Council of Scientific and Indus-
trial Research (CSIR), New Delhi, India, for funding the work
reported in this paper.
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