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Investigation on sliding wear behaviour of

UHMWPE filled basalt epoxy composites


Cite as: AIP Conference Proceedings 2057, 020048 (2019); https://doi.org/10.1063/1.5085619
Published Online: 11 January 2019

N. Mohan, R. Ashok Kumar, K. Rajesh, Ramanath Prabhu, S. Preetham, A. N. Rakshith, and M. Akshay
Prasad

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AIP Conference Proceedings 2057, 020048 (2019); https://doi.org/10.1063/1.5085619 2057, 020048

© 2018 Author(s).
Investigation on Sliding Wear Behaviour of UHMWPE
Filled Basalt Epoxy Composites

,, N. Mohan1,a), R. Ashok Kumar2,b), K. Rajesh. 1,c), Ramanath Prabhu 3,d),


S. Preetham 4, e), A. N. Rakshith4,f) and M. Akshay Prasad4,g)
1
Department of Industrial Engineering and Management, Dr.Ambedkar Institute of Technology, Bangalore.India.
2
Department of Mechanical Engineering, The Oxford College of Engineering, Bangalore, India
3
Department of Chemistry, RNS Institute of Technology, Bangalore, India
4
Department of Mechanical Engineering, RNS Institute of Technology, Bangalore, India

a)
Corresponding author: drmohannagaraj@gmail.com
b)
shrinandt@gmail.com
c)
rajesh_kivade77@yahoo.com
d)
prabhu.ramanath14@gmail.com
e)
preetham035@gmail.com
f)
rakshi.raj.77@gmail.com
g)
akshayprasadmj@gmail.com

Abstract. Natural woven mineral fiber quarried on the surface of the volcanic rocks. Which are the best competitors for synthetic
fiber reinforcement in polymer based composite for different applications. This study introduces to low density fillers
incorporated into a mineral based basalt fiber in the polymer composite research world. In the present research investigations as
made of ultra-high molecular weight polyethylene (UHMWPE) filled basalt-epoxy (B-E) composites on dry sliding wear
behavior and the findings were analyzed. Composite specimen was prepared by using a resin transfer molding (RTM) technique.
Dry sliding wear investigation as analyzed by using a sliding wear test rig. The sliding wear rate of composites reduced by the
incorporation of UHMWPE in to B-E composites. This reduction in sliding wear properties is obtained by the formation of a
tribo-film on the steel counter face and which acts as load bearing material to prevent damage of fiber and matrix. The worn
surface features have analyzed through scanning electron microscopy (SEM), and results reveals that severe damage to the matrix
and fiber in the B-E composite specimen as compared to filler loaded composites.
Key words: Basalt, Epoxy, UHMWPE, Wear mechanism.

INTRODUCTION
The fiber-reinforced polymer matrix composites are extensively used in tribological sectors because of their
light weight, high strength-to-weight ratios, and resistance to corrosion being easy to fabricate, design flexibility and
better tribological properties as compared to metal parts. It has been reported that various applications of FRP in
equipment exposed to sliding wear conditions. The FRP composite parts, bearing liner, pipe liners, sleeves, pressure
pipes, tank liners, infill panels, brake pads, seals and bushings etc., find extensive application in automobile sectors.
Epoxy matrix exhibits high strength, lightweight, self-lubrication and low wear loss in tribological environment
hence it is used as load bearing applications in automobile and novel sectors in low energy transfer sliding wear
situations [1]. Wear is one important issue that will affect the life of components in tribological environment like
adhesive, abrasive and erosive. The friction between the components increases the temperature which will cause the
loss of wear and which leads to the replacement of components and introducing new wear resistance, light weight,
high strength and temperature withstand materials are important in sliding wear applications [ 2,3].
V.ArugaPrabu.et.al [4] investigated wear and friction on red-mud filled banana fiber composites by using statistical

Advances in Polymer Composites: Mechanics, Characterization and Applications


AIP Conf. Proc. 2057, 020048-1–020048-10; https://doi.org/10.1063/1.5085619
Published by AIP Publishing. 978-0-7354-1785-4/$30.00

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analysis and he concluded that 10 wt.% silica sand filled material system exhibits a lower wear rate at 10N load,
3000m sliding distance and at 3m/Sec sliding velocity. The research work of Sandeep Kumar et.al [5] reported that
the friction coefficient and specific wear rate of CaCO3 incorporated filler in polymer matrix composite system
shows decreases the specific wear rate with the increase of filler content on dry sliding wear condition. S. Srinivas
Murthy et.al [6] made a survey of the optimization approach in wear properties of particulates filled fiber reinforced
composites and they reported that minimum wear rate obtained by adding a filler content up to 17 wt%, at 0.511 Kg
lower loads. J. Sudeepanet.al [7] investigated on wear characteristics of ABS/CaCO 3 composites using a statistical
method and author concluded that applied load is the significant factor and this was effected the coefficient of
friction. G.S Gill et al. [8] observed that sliding wear characteristics of B 4C, WS2 filled epoxy composite were
analyzed by using the Taguchi design of experiments. The influencing operating parameters like load, speed, and
time, which affect the specific wear rate most dominant factor in this investigation is the normal load followed by a
percentage of filler, time and speed. It is also concluded that engineering components subjected to wear situation are
successfully prepared by the filling of micro-WS2 and B4C are the promising candidate in an epoxy matrix.
Ashutosh Pattnaiket.al [9] investigated tribological characteristics of fly ash filled epoxy composite by using
Taguchi techniques and they concluded that the fly fiery debris can also be utilized for dry sliding wear application.
The applied normal load is the most dominant factor by varying friction force, wear rate and friction coefficient and
it is followed by speed, time and track diameter. Mohan et.al [10] reported that utilization of tungsten carbide and
tantalum niobium carbide filler in glass epoxy composites on tribological properties they concluded that a hard
powder in glass fiber significantly reduces the wear loss at all the conditions. Hemanth et.al [11] analyzed abrasive
wear behaviour of polyester based composite material. A statistical method reported that additions of fillers and
fibers in TCE affect the wear resistance of the specimens. The wear properties can be increased by the incorporation
of 20wt.% of SGFs and further increased by 20wt.% of ceramic filler. Y.An El-SheKeil.et.al [12] reported on
optimization techniques of basalt fiber-reinforced polyurethane composites a taguchi technique and he concluded
that optimum parameters that can result in tensile strength are speed (50rpm), time (13min), fiber size (125-130
microns) and temperature (180C0). N. Mohan et al. [13] studied on the wear behavior of graphite loaded glass epoxy
composites at varying temperature and he concluded that the lower the wear resistance observed at unfilled
composites as compared to filled composite system. The wear behaviour is the synergistic effect on applied load and
temperature. B. N. Ramesh et. al [14] studied tribological characteristics of carbon epoxy composite samples filled
with molybdenum disulfide (MOS 2) and alumina fillers with different compositions. The experiments were carried
out as per taguchi L18 array. The result showed filler loading, and grit size was the most prominent factors in
regulating the wear rate of carbon epoxy composite. T. B. Yallew et. al. [15] Fabricated jute fiber reinforced PP
composites, the wear behavior was analyzed by a computerized dry sliding wear testing machine with different
parameters on dry sliding wear condition with varying operating condition (distance, load, and velocity). From this
study with the addition of jute fiber as a coating into PP matrix results in 65wt.% contraction in specific wear rate
and 45wt.% reduction in the friction co-efficient. Siddhartha et al. [16] studied wear behavior of particulate filled
homogeneous composites, he concluded that kiln dust particles improve the wear properties of resin, and uniform
distributed dust particles in resin system shows lower the wear loss as compared to functionally graded samples.
Hiral. H. Parikh et al. [17] reported on the experimental investigation on natural cotton fiber reinforced
thermoplastic based polyester material. This study observed that varying the wear properties by the addition of filler
in composite systems. The results show that 5wt. % of graphite filler in CFPC increases the wear resistance
compared up to 3wt. % of the graphite CFPC composite system. Chauhan.et.al [18] studied the effect of friction on
dry sliding wear behavior of of fly ash filled glass-vinyl ester matrix and the author concluded that wear properties
has improved by the addition of flyash filler. Ahmed.et.al [19] investigated on mechanical properties of
Epoxy/Nanoclay/Multi-Walled carbon Nano tube composites using statistical methods and concluded that the
taguchi technique was found to be an effective method to optimize the tensile modulus, impact fracture toughness,
tensile strength and impact strength. Mohan.et.al [20] studied abrasive wear behaviour of SiC filler incorported
polymer based composites and concluded that incorporation of optimum fillers in matrix shows the better wear
resistance. The effect of fillers shows the synergistic effect on both reduced wear and improved different tribological
properties. Yashvir Singh.et.al [21] reported that comparative studies on Pongamia and Jatropha as lubricant
additives on En31 steel disc and concluded that 15wt.% Pongamia and Jatropha shows better antifriction
characteristics at elevated load condition.
The presence of UHMWPE in the basalt epoxy system is expected improves the wear properties. The
UHMWPE reinforced composite specimen showed enhanced wear resistance in mining applications [22-23]. Many
researchers used UHMWPE as a secondary material in polymer matrix composites [24-29] the combination is
limited to basalt fibers and epoxy matrix. The present investigation explores the possibility of using UHMWPE in

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epoxy matrix and to study the wear behavior of 2 wt. % and 4 wt. %. UHMWPE in basalt epoxy (B-E) composite
and which is rubbed against En32 steel disc with varying load condition and it opens a new way to implement
UHMWPE product as filler in a dry sliding wear environment especially in automotive bearing liner applications.

EXPERIMENTAL
Materials and Manufacturing of hybrid composite specimen
Bidirectional basalt fabric 360 g/m2 was procured from M/s. ATTPvt. Ltd. Mumbai, India (Fig.1). The
basalt fabric of dimension 20 μm diameter was used as reinforcement. Bi-functional epoxy resin (LY 5052) and
Cyclo-aliphatic amine (HY 5052) hardener was obtained from M/s. Naphtha Resins & Chemicals, Peenya, India.
The commercially available UHMWPE of particle size varying up to 26 μm was used as filler (Fig.2).
Basalt fiber is an inorganic fiber, the important properties are high strength, high modulus, high strain rate,
withstands temperature up to fracture, excellent stability, good chemical resistance, non-toxic, natural, eco-friendly
and it is easy to process in all matrix material has excellent load-bearing properties. The basic constituents of basalt
fabric are, CaO, MgO, K2O, Na2O, Fe2O2, FeO, SiO2, and Al2O3, [30] The presence of rich silica 58% and alumina
17% of basalt fiber shows excellent wear resistance performance in the different tribological sector.
Low impact resistance, low toughness thermosetting brittle in nature epoxy based resins which will not
give excellent sliding wear resistance. The use of fillers in the resin system provides higher the load bearing
capability, moderated coefficients of friction, improved wear resistance, better thermal properties and increased
mechanical strength. The wear resistance of epoxy matrix can be enhanced by the addition of a second phase filler
like ultra-high molecular weight polyethylene (UHMWPE). A property of ultra-high molecular weight polyethylene
that distinguishes it from other polymers is its highly entangled molecular chains, which makes it high wear
resistant. UHMWPE is a long chain wear resistant polymer with a moderate coefficient of friction rubbed against
steel disc [31-33]. The wear properties of UHMWPE, become a major focus on the long-term performance of
composite, hence the present investigation has focused on basalt fiber reinforced with UHMWPE filled epoxy based
composite and to investigate the dry sliding wear with different loading conditions.
The preparation and processing of composite specimens are as follows: (a) epoxy resin and fillers mixed by
using a mechanical stirrer, (b) curing agent is applied by mixed fillers in epoxy resin, and (c) fiber wetting (d)
consolidation and (e) curing of fabricated composites. In the first stage (a), a proper quantity of filler is mixed with
epoxy resin using a high speed mechanical stirrer to improve the proper dispersion of filler in the epoxy resin. In the
second stage (b), the hardener is mixed into the filled epoxy resin using a mechanical stirrer. To get a proper
distribution of UHMWPE in epoxy resin by using mechanical stirrer and centrifugation process was taking place,
due to low density UHMWPE powders floats on the surface of the resin and to avoid the floating of low density
particles on top surface the centrifugation process have incorporated and by using centrifugal machine to centrifuge
the filler mixed resin and layup sequence of the fabric and filler filled resin are process in between the floating and
settling of UHMWPE filler in epoxy matrix and also check the time elapsed between floating and settling of filler in
resin system and continue the fabrication process with uniform distribution of fillers in resin system. The centrifugal
method of mixing of filler in epoxy matrix process as followed by elsewhere [34].

(a) (b) (a) (b)

FIGURE 1. Basalt fiber before Test Magnification 0.5 KX and FIGURE 2. (a) UHMWPE powder 14 to 26 Microns
1KX 0.5KX and (b) UHMWPE filled B-E composite of
magnification1.8K

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The ratio of epoxy matrix of hardener was 100:38 on a weight basis. From stage (c) to (e) the composites
were prepared using the resin transfer molding technique with channelized passing off vacuum (Fig. 3) and
fabrication process as follows by elsewhere [35]. With the help of metallic template cutting of fabrics into required
dimensions. A good and cleaned plain surfaced mould was used for fabrication and by using a vacuum pump to
remove any dust, dirt present on the surface of the mould before laying up of fabrics a suitable releasing agent called
wax was applied. Fabrics are arranged layer by layer on the surface of the mould. The peel ply and breather was
placed on the top layer of the basalt fabric. Easy removal of the specimen from the bag, a peel ply was introduced in
between vacuum bag and breather and also ensure uniform circulation of vacuum.
A suitable sealant was fixed across and around the fabrics at a distance of about 100mm, tubes were
attached and connecting to a vacuum pump. Air is removed by a vacuum pump and maintained at 1Mpa of pressure,
and an epoxy resin is transferred into the lay-up to wet the fabrics. On stage (d) after wetting of layers, the vacuum
bag was removed. Once again the whole assembly was covered with vacuum bag with introducing a new peel ply
and breather and maintaining a pressure up to 1Mpa. To reduce the voids and dry spots and improve the
consolidation the matrix was smeared onto the fabric before the process of resin is transferred into the mold. In the
step (e), the fabricated panels were post cured up to 120 0C for 3 hours in an autoclave. Flow chart of the fabrication
process of composites is shown in Fig.4.
The ratio of basalt fiber: matrix (epoxy): filler was 60:37:3 and 60:34:6. The unfilled basalt fiber epoxy
composites are designated as B-E, UHMWPE filled B-E composites as B-E-U1 (60:37:3) and B-E-U2 (60:34:6) the
details as shown in Table 1. The laminate of dimensions 300 mm x 300 mm x 1.5 + 0.2 mm was fabricated and
specimens of size 5mm × 5mm were cut using a diamond tipped cutter.

TABLE 1. Composite specimen designation and code

Composite Material Code Weight % of Weight % of Weight % Filler


Fiber Matrix

Basalt-epoxy composite B-E 60 40


3wt.% UHMWPE Filled B-E B-E-U1 60 37 3
6wt.% UHMWPE Filled B-E B-E-U2 60 34 6

Technique
Dry sliding wear test was conducted by using a pin-on-disc as per ASTM-G99 standard. The fabricated
specimen of size 5 mm x 5 mm x 2.6 mm was glued to the pin of dimension of 10 mm diameter and 25 mm height
which came in contact with a hardened En32 steel disc of hardness 52 HRC. To obtain a surface roughness of 0.65
μm of steel disc polishing the disc by using SiC emery paper of 800 grade. The test pin was mounted on the lever-
arm. The applied normal loads varying from 10 to 50 N in steps of 10 N, sliding velocity 8.0 m/s, and at a constant
sliding distance of 4000 m. The surface of the specimen was cleaned by using soft tissue paper soaked in acetone
and clean the surface of the specimen by using compressed air before and after the test. The specimen initial height
was recorded using a transducer set up in the testing machine. The difference between initial and final height of the
specimen was a measure the slide wear loss and wear volume loss is calculated by the product of the specimen depth
loss (height “h” in mm) and cross-sectional area of the specimen (b x l in mm2). The average of three trials ensures
the error free test data. The digital photograph of pin-on-disc (POD) machine used is as shown in the Fig. 5. The
specific wear rate (Ks) was calculated from the equation (1):

Where ∆V volume loss of the specimen in mm3, L is the applied normal load in Newton and d Sliding distance in
mm

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FIGURE 3. Diagram of resin transfer moulding arrangement (a) Granit table, (b) Basalt fabrics, (c) breather material and
peel ply (d) Vacuum distribution channel, (e) Bagging with uniform channelized distribution of vacuum,
(f) Matrix+ UHMWPE inlet and (g) Outlet vacuum channel.

FIGURE 4. Processing of composite specimen

FIGURE 5. Photograph of a dry sliding pin-on-disc wear test rig, Dept. of IEM Research Centre, Dr.AIT-Bangalore

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RESULTS AND DISCUSSION

Wear volume loss and specific wear rate


Wear volume loss as a function of varying applied normal load (From 10N to 50N), at the speed of 8m/s
and at a constant track distance of 4000m of unfilled and filled (UHMWPE) filled B-E composite system is as
shown in Fig.6. From the figure it is observed that the wear volume loss increases with increases an applied load. As
compared to unfilled composite a filler filled composite system shows lower wear volume loss at all the conditions
and applied load. The presence of filler UHMWPE in the composite system reduces the wear loss and formation of a
tribo film on the surface of the steel counter face. At lower load of (10N) wear volume loss of unfilled composite
shows 0.29 mm3 and 6wt. % (UHMWPE) filler filled composite shows 0.2 mm 3 at higher load of (50N)
condition wear volume loss of unfilled composite shows 16 mm3 and filler filled composite shows 6.1 mm 3. From
the quoted references [36-39] the obtained result was good agreement with the operating parameters and wear
volume loss of the composites. The wear volume loss of the unfilled B-E composite is much higher than UHMWPE
filled B-E composite at all experimental conditions under investigation. At higher loads increase in interracial
temperature and thermal softening of the matrix with wear powders consists of broken short fibers including
alumina and silica particles spreads on the surface of the specimen which reduces the further toughness and broken
pulverized basalt particles contains fiber+Epoxy+UHMWPE, which leads to reduces the smoothness of steel disc.
The UHMWPE filled B-E specimen improves the wear resistance at different loading condition. The basalt
fabric strengthens the composite and presence low density UHMWPE particles in epoxy matrix act as lubricants and
to prevent the damage of epoxy and fracture of fiber. As the increasing percentage of filler from 3wt. % to 6wt. % a
synergistic effect was observed and reduces wear volume loss.

FIGURE 6. Wear volume loss v/s normal load at constant sliding distance 4000m and at constant velocity 8m/s

The graphical representation of specific wear rate versus applied load at sliding velocity 8 m/s and at
constant sliding distance of 4000 m as shown in Fig.7. The specific wear rate of the composites increased with
respect to increasing the load as compared to unfilled composites the UHMWPE filled composite shows lower the
value of specific wear rate at all the condition. . On increasing the applied load from 10N to 20 N the specific wear
rate reduces drastically, indicates at lower load. However, with further load is increased above 20 N the specific
wear reduction rate was found to reducing down. The variation of wear rate with applied load from 20 to 40 N
obtain a linear wear behaviour. This can be studied by following reasons: (i) initially when the composite specimen
is in contact with the steel counterface the specific wear rate is high and (ii) with increase in applied load the worn
particles spreads on the surface of the specimen and slows down further wear. At lower loading, low modulus
matrix was exposed to the sliding surface and hence, high specific wear rate. At higher loading condition high
modulus basalt fabric was exposed to sliding surface, which showed high specific wear rate. This is due to their high
hardness value of the fibers shows better wear resistance rubbing against steel counterpart and in turn, higher
amount of energy is required to facilitate fiber failure. Thus, the rate at which the material is removed with respect to

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the lower loading decreases as compared to higher loading condition. The obtained wear behaviour has explained by
Mohan et.al.[40-44] investigated dry sliding wear behaviour of jotropha oil cake filled glass epoxy composites,
found that specific wear rate increases with increasing the applied load and influence of filler shows synergistic
effect an applied load and filler acts as a antiwear additives at all tribological conditions. As compared to B-E
composite, the B-E-U2 composite shows lower specific wear rate. This is due to highly entangled molecular long
chain UHMWPE in B-E composites which with stands load bearing capacity and formation of thin layer on
the counter face, which reduces further wear rate. The wear resistance offered by different composite system is in
the order of B-E< B-E-U1<B-E-U2.
The larger specific wear rate (KS) of 8 x 10-15 mm3 /N-mm for unfilled B-E composite at 50N load and
lowest (KS) of 1.25 x 10-15 mm3 /N-mm for UHMWPE filled B-E composite at 20N load were observed. The
specific wear rate was reduced after incorporation of UHMWPE filler in BE composite.

FIGURE 7. Specific wear rate as a function of applied normal load of different composites

Worn surface morphology


The worn surface morphology of composite specimen is analyzed by using SEM. The SEM features of
worn out surface at lower load of 10 N for unfilled B-E composite (Fig. 8) Indicates breakage of a matrix and
exposure of fibers as observed, which is due to the poor interfacial adhesion between fiber-matrix which caused a
reduces bond strength. As increasing the applied load 50N (Fig.9) indicates alternative series of fiber breakage and
formation of matrix debris in the interfacial region. The UHMWPE filled B-E composite specimen at lower load
10N condition from the Fig. 10 the worn surface shows enhances the bonding strength of filler in B-E composites
and protects the fiber and matrix from damage and some fillers spreads over the surface of the specimen and which
acts as an anti-wear additives and further it reduces the wear with respect to the load. From Fig.11 (50N) indicates
that fillers act as a load bearing material and which takes some part of the load, increased contact temperature, and
increases the softening of the specimen contact surface. The softening nature of UHMWPE in epoxy matrix
produces a thin tribo-film on the steel disc which acts as solid lubricants and reduces further damage of the
specimen and partially visible of few fibers and reduced surface fracture significantly. The worn surface features
correlate the obtained wear data from the Figures 6 and 7. Thus, in the present investigation, the B-E composite
system exhibits an increase in wear loss with respect to the applied load.
(a) (b)

FIGURE 8. SEM image of B-E Specimen at 10N load 0.5K FIGURE 9. SEM image of B-E Specimen at 50N load,0.5K

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(a) (b)

FIGURE 10. SEM image of B-E-U2 Specimen at10N load FIGURE 11. SEM image of B-E-U2 Specimen at 50N load
0.5K 0.5K

CONCLUSIONS
The study of the wear properties of UHMWPE filled and unfilled B-E composite system at varying applied load is
as follows.
The wear behaviour of unfilled basalt-epoxy composite possesses strong relation with the applied load. The
enhancement of the wear performance of UHMWPE filled Basalt-epoxy composite is associated with less
fiber / matrix loss.
The specific wear rate increases with an increase in the applied load.
The surface morphology of the worn surface show matrix breakage, matrix debris formation, fiber
breakage and exposure of fibers due to low wear resistance of the matrix.

ACKNOWLEDGEMENTS
The authors wish to express their gratitude for the provision of the excellent experimental facilities,
provided at research Centre of Department of Industrial Engineering and Management, Dr.Ambedkar Institute of
Technology. One of the authors, Dr. N. MOHAN is great full to the management and Dr.C.Nanjundaswamy,
Principal and Dr.G.Rajendra, HOD Dept.of IEM of the Dr. Ambedkar Institute of Technology, Bangalore and the
Principal and HOD Dept. of Mechanical Engineering, RNS Institute of Technology, Bangalore and also the
organizing committee of ICPC-2018, NITK for their help and valuable support for this research work and
publication.

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