Investigations for Performance Analysis of Ceramic Composites for

Bearing Applications
Gourav Mittal, IKG Punjab Technical University, Jalandhar, India
Rupinder Singh, Guru Nanak Dev Engineering College, Ludhiana, India
Gurinder S Brar, NIT Uttarakhand, Srinagar, Uttarakhand, India
r 2018 Elsevier Inc. All rights reserved.

1 Introduction 1
2 Materials and Methods 1
3 Discussion on Case Study and Process Flow Chart 4
4 Conclusions 6
Acknowledgement 6
References 6

1 Introduction

A bearing is a mechanical element which converts one motion into another motion and reduces friction between the moving
machine elements. There are various types of bearings like radial bearings, thrust bearings according to type of load they have to
support and sliding contact bearing, rolling contact bearings according to their contact nature (Harsha, 2006). In sliding contact
bearings the sliding action takes place along the contact surfaces between the moving machine element and fixed machine
element. The sliding contact bearing is also called plain bearings or sleeve bearings. In rolling contact bearings, the steel balls or
rollers are introduced between the moving machine element and fixed machine elements. The balls serve rolling friction at two
points for every ball or roller (Tung and McMillan, 2004).
Metal alloys are generally used in applications where wear resistance properties of materials are required as they can be easily
machined, ground or forged for various wear resistant parts that have properties different from ceramics (Ezugwu et al., 2003).
Although, metals have high toughness but low strength, low hardness and wear resistance properties than ceramics.
Ceramics have high thermal resistance; high hot strength and very good wear resistance properties but have low thermal shock
resistance. Thermal shock is basically a function of thermal expansion and thermal conductivity. In last 10 years lot of work has
been reported to overcome the thermal shock. One of the solutions is found in composite materials. As an example aluminum
oxide nano-fiber can improve the ductility of ceramic metal composites, keeping Young’s modulus high while increasing creep
resistance and decreasing brittleness (Das and Balla, 2015).
One of the methods for creating ceramic composites is mixing nonmetallic fibers with a ceramic matrix and sintering the
component in a mold or supporting structure (Hammel et al., 2014). The chemical vapour infiltration technology is attractive
method to produce fiber – reinforced ceramic matrix composites using this technique strong and tough composites can be
prepared with good corrosion, erosion, and wear resistance properties (Lazzeri, 2012). The addition of Al-6%Si alloy reinforce-
ment in ceramics increases the linear shrinkage, strength and impact energy but density, porosity and hardness decreases
(Aigbodion et al., 2010).
For making power transmitting elements which are under continuous loading conditions Al-SiC metal-matrix composite can
be used which possesses high strength, high stiffness, thermal stability at elevated temperatures, high corrosion and wear
resistance and more fatigue life (Pawar and Utpat, 2014). Addition of SiC weight percentage in aluminum based composite
material increases the micro-hardness and compressive strength (Jeevan et al., 2012)). The strength of mullite-SiC ceramic
composite depends upon the phase composition, relative density and the percentage addition of SiC. Good mechanical
properties of ceramic composite can be obtained with 20% wt. addition of SiC (Akpinar et al., 2012). The strength and
toughness of mullite-SiC composites possesses higher strength and toughness as compared to monolithic mullite. Flexural
strength varies from 646 to 855 MPa of composite as compared to 202 MPa for monolithic mullite (Singh and Gaddipati,
1988). Sintered mullite-SiC ceramic composite possesses good crack healing ability and crack-healed specimens have higher
static and fatigue strengths than the normal specimens (Ando et al., 2001). The literature review highlights that some studies has
been reported on the improvement of mechanical and tribological properties of ceramic matrix composite materials but very
less has been reported for improving properties of sleeve bearing by using ceramic metal matrix composite. This is important
from process view point as because in bearing applications, one has to make tight balance between the properties of bearing
material and moving element like shaft. In the present study, an attempt has been made to prepare mullite and SiC ceramic
matrix composite material by using powder metallurgy technique to improve the properties of material which can be used for
making sleeve bearings.

Reference Module in Materials Science and Materials Engineering doi:10.1016/B978-0-12-803581-8.11408-0 1

2 Investigations for Performance Analysis of Ceramic Composites for Bearing Applications

Fig. 1 Ball mill (3D view used in present study).

Fig. 2 Green compact sample prepared on hydraulic press.

Table 1 Different conditions set for sintering process during pilot experimentation

Sample no. Composition Sintering temperature Sintering atmosphere

1 90% Mullite, 10% SiC 15001C Ambient air

2 90% Mullite, 10% SiC 15501C Inert gas
3 90% Mullite, 10% SiC 16001C Inert gas

Fig. 3 Microwave sintering furnace.

 Investigations for Performance Analysis of Ceramic Composites for Bearing Applications 3

Fig. 4 Sintered samples.

Fig. 5 Surface image using metallurgical microscope (at X100).

Table 2 Results for Porosity and Grain size

Sample no. Porosity Avg. grain size

1 86.25% 0.2581
2 94.9% 0.2581
3 84.16% 0.2581

2 Materials and Methods

The ceramic matrix material mullite (3Al2O32SiO2) in powder form was procured from local market (Sigma Aldrich Company,
Bangalore, India) and SiC powder was procured from Central Drug House, New Delhi, India. In order to make ceramic matrix
composite both the powders were mixed with binder polyvinyl alcohol (PVA) in laboratory ball mill (see Fig. 1). Initially mullite
powder 90% (by weight), SiC 10% (by weight) was mixed with PVA binder 5% (by weight) in ball mill for 8 h for making
homogeneous mixture.
The homogeneous mixture thus prepared was compacted on hydraulic press for making green compact (see Fig. 2). The
mixture was pressed in die with hydraulic press at 220 MPa load for making green compact samples.
The green compact ceramic composites were processed further for microwave sintering. Three samples were sintered under
different conditions as per Table 1 by using 2.45 Hz microwave sintering furnace (see Fig. 3). Based upon different input
conditions set as per Table 1, Fig. 4 shows finally procured sintered samples.
After sintering, porosity and average grain size of sintered samples was checked. To check porosity and grain size samples were
observed with metallurgical microscope supported with image analyzing software for surface image of samples (see Fig. 5). Based
upon Table 1, Table 2 shows results of porosity and grain size.
4 Investigations for Performance Analysis of Ceramic Composites for Bearing Applications

Fig. 6 Pin on disc apparatus.

Table 3 Observations for wear on pin on disc setup

Sample no. Load (kg) Time (min) Speed (rpm) Track Dia. (mm) Wear (mm) Frictional force (N)

1 5 25 300 80 86 14.3
2 5 25 300 80 87 14.4
3 5 25 300 80 126 8.5

For establishing the properties of the ceramic matrix composite wear test was performed on pin on disc apparatus (Tribometer)
as shown in Fig. 6. Table 3 shows observations of wear properties.
Table 3 outlines that no significant wear was observed in all the samples hence the composite matrix possesses good wear
properties. For establishing high temperature application of ceramic matrix composite differential scanning calorimetry (DSC)
analysis was performed (see Fig. 7) for three repeated cycles up to 4001C. Based on Fig. 7, Table 4 shows the results of energy
absorbed per unit gm by ceramic matrix composite.
As observed from Fig. 7 and Table 4, it is clear that the sample 1 (which was heated to 15001C) has high thermal stability
(required for the bearing material working at high temperature) as compare to sample 2 and sample 3, which were sintered to
15501C and 16001C respectively.

3 Discussion on Case Study and Process Flow Chart

In the present case study, mullite powder 90% (by weight), SiC 10% (by weight) with PVA binder 5% (by weight) has been
initially processed on ball mill, followed by preparation of green on hydraulic press and sintering in microwave. Based upon Fig. 5
and Table 2, it has been ascertained that uniform grain size has been achieved with high surface porosity. This high surface porosity
is really appreciable in bearing applications as more quantity of lubricant (as film) can be accommodated. The results of the wear
analysis (Table 3) outlined very small/ negligible wear; hence make this route acceptable for bearing applications. Finally the DSC
analysis outlined that energy absorbed per unit gm in case of sample 1 is more than as compared to sample 2 and 3 (see Table 4
and Fig. 7). Further there was no thermal deformation up to 4001C. Hence the proposed ceramic matrix composite can be used for
high temperature applications. The results are in line with the observations made by other investigators (Pawaskar and Prasad,
2014). The proposed process flow chart for performance analysis of ceramic composites in bearing applications is shown
in Fig. 8.
 Investigations for Performance Analysis of Ceramic Composites for Bearing Applications 5

Fig. 7 DSC curves for the three samples (as per Table 1).

Table 4 Energy absorbed per unit gm (by the prepared samples as per Table 1)

Sample no. Mass of sample (mg) Total energy absorbed (mW) Energy absorbed per unit gm (mW)

1 6.9 2.9 0.420

2 10.1 2.225 0.220
3 10.2 2.5 0.245

Processing of mullite powder 90% (by weight),

SiC 10 % (by weight) with PVA binder 5% (by weight)
on Ball mill

Preparation of green compact sample on hydraulic press,

followed by Microwave sintering of green samples

Porosity, grain size and wear analysis

Thermal stability analysis

Fig. 8 Process flow chart for preparation of sleeve bearing (by proposed route).

For ascertaining the high temperature bearing applications, further studies may be conducted on lubricant film thickness under
different loading conditions on test rig. Finally for preparing the industrial standard for the proposed route, study needs to be
conducted (by following a design of experiment technique) with different levels of mullite, SiC proportion/composition, different
pressure variation while preparing the green sample, temperature and inert gas variation in microwave sintering furnace.
6 Investigations for Performance Analysis of Ceramic Composites for Bearing Applications

4 Conclusions

Following are the conclusions from the present study:

(1) The mullite and SiC based ceramic matrix composite has been successfully prepared by microwave sintering process. It has
been observed that ceramic matrix composite possesses good wear resistance properties.
(2) Further photo-micrographic analysis outlines that mullite and SiC based composites are suitable for sleeve bearing as its
porosity is very good which is required for self lubrication. Based upon DSC analysis, it has been ascertained that mullite and
SiC based composites are thermally stable up to 4001C, when they are sintered to 15001C.

Acknowledgement

The authors are thankful to IKGPTU Jalandhar and Manufacturing Research Lab (Production Engg. Dept.), GNDEC Ludhiana for
financial and technical support.

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