Skip to main content
SpringerLink
Log in

The Competing Effects of Counterface Peaks and Valleys on the Wear and Transfer of Ultra-Low Wear Alumina–PTFE

  • Original Paper
  • Published:
Tribology Letters Aims and scope Submit manuscript

Abstract

The wear rates of tribological polymers are strongly influenced by counterface roughness through competing mechanisms such as polymer abrasion by counterface asperities and mechanical engagement of debris into the features of the rough surface. Previous studies have shown that an ultra-low wear (k ~ 10−7 mm3/Nm) alumina–PTFE solid lubricant loses wear resistance and the ability to form stable transfer films when the counterface roughness exceeds a critical magnitude or aligns with the sliding direction. In this paper, we aimed to test the independent effects of counterface peaks and valleys on polymer wear and transfer using this well-studied alumina–PTFE system. Wear tests were performed against 304 stainless steel counterfaces of systematically varied peak height and valley depth. Interrupted microscopy measurements were used to record the details of debris engagement, migration, aggregation, and removal. Preferential removal of the tallest peaks on the counterface helped stabilize the transfer films and dramatically reduced the transient wear volume of the polymer composite even on very rough surfaces. The results illustrate the independent and competing effects of counterface peaks, plateaus, and valleys on the wear and transfer of this ultra-low wear polymer composite. While increased peak height promoted primary material removal from the polymer composite and inhibited the formation of the transfer film, intersecting valleys and smooth plateaus helped nucleate and stabilize transfer films. On rough surfaces with tall peaks, the composite eventually achieved ultra-low wear by gradually removing the tallest asperities to achieve a more favorable topography for transfer film formation.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13

Similar content being viewed by others

References

  1. Briscoe, B.J., Tabor, D.: The sliding wear of polymers: a brief review. Fundam. Tribol. 25, 733–758 (1980)

    Google Scholar 

  2. Dasari, A., Yu, Z.-Z., Mai, Y.-W.: Fundamental aspects and recent progress on wear/scratch damage in polymer nanocomposites. Mater. Sci. Eng. R Rep. 63, 31–80 (2009)

    Article  Google Scholar 

  3. Friedrich, K., Zhang, Z., Schlarb, A.K.: Effects of various fillers on the sliding wear of polymer composites. Compos. Sci. Technol. 65, 2329–2343 (2005)

    Article  Google Scholar 

  4. Sawyer, W.G., Argibay, N., Burris, D.L., Krick, B.A.: Mechanistic studies in friction and wear of bulk materials. Ann. Rev. Mater. Res. 44, 395–427 (2014)

    Article  Google Scholar 

  5. Ye, J., Burris, D.L., Xie, T.: A review of transfer films and their role in ultra-low-wear sliding of polymers. Lubricants 4, 4 (2016)

    Article  Google Scholar 

  6. Burris, D.L., Boesl, B., Bourne, G.R., Sawyer, W.G.: Polymeric nanocomposites for tribological applications. Macromol. Mater. Eng. 292, 387–402 (2007)

    Article  Google Scholar 

  7. Harris, K.L., Pitenis, A.A., Sawyer, W.G., Krick, B.A., Blackman, G.S., Kasprzak, D.J., et al.: PTFE tribology and the role of mechanochemistry in the development of protective surface films. Macromolecules 48(11), 3739–3745 (2015).

    Article  Google Scholar 

  8. Pitenis, A.A., Harris, K.L., Junk, C.P., Blackman, G.S., Sawyer, W.G., Krick, B.A.: Ultralow wear PTFE and alumina composites: it is all about tribochemistry. Tribol. Lett. 57(1), 4 (2015)

    Article  Google Scholar 

  9. Krick, B.A., Ewin, J.J., McCumiskey, E.J.: Tribofilm formation and run-in behavior in ultra-low-wearing polytetrafluoroethylene (PTFE) and alumina nanocomposites. Tribol. Trans. 57, 1058–1065 (2014)

    Article  Google Scholar 

  10. Blanchet, T.A., Kandanur, S.S., Schadler, L.S.: Coupled effect of filler content and countersurface roughness on PTFE nanocomposite wear resistance. Tribol. Lett. 40, 11–21 (2009)

    Article  Google Scholar 

  11. Burris, D.L., Sawyer, W.G.: Tribological sensitivity of PTFE/alumina nanocomposites to a range of traditional surface finishes. Tribol. Trans. 48, 147–153 (2005)

    Article  Google Scholar 

  12. Blanchet, T.A., Kennedy, F.E.: Sliding wear mechanism of polytetrafluoroethylene (PTFE) and PTFE composites. Wear 153, 229–243 (1992)

    Article  Google Scholar 

  13. Wang, Y., Yan, F.: A study on tribological behaviour of transfer films of PTFE/bronze composites. Wear 262, 876–882 (2007)

    Article  Google Scholar 

  14. Wang, Y., Yan, F.: Tribological properties of transfer films of PTFE-based composites. Wear 261, 1359–1366 (2006)

    Article  Google Scholar 

  15. Urueña, J.M., Pitenis, A.A., Harris, K.L., Sawyer, W.G.: Evolution and wear of fluoropolymer transfer films. Tribol. Lett. 57(1), 9 (2015)

    Article  Google Scholar 

  16. Ye, J., Moore, A.C., Burris, D.L.: Transfer film tenacity: a case study using ultra-low-wear alumina–PTFE. Tribol. Lett. 59, 1–11 (2015)

    Article  Google Scholar 

  17. Krick, B.A., Ewin, J.J., Blackman, G.S., Junk, C.P., Gregory Sawyer, W.: Environmental dependence of ultra-low wear behavior of polytetrafluoroethylene (PTFE) and alumina composites suggests tribochemical mechanisms. Tribol. Int. 51, 42–46 (2012)

    Article  Google Scholar 

  18. Onodera, T., Kawasaki, K., Nakakawaji, T., Higuchi, Y., Ozawa, N., Kurihara, K., et al.: Chemical reaction mechanism of polytetrafluoroethylene on aluminum surface under friction condition. J. Phys. Chem. C 118, 5390–5396 (2014)

    Article  Google Scholar 

  19. Onodera, T., Kawasaki, K., Nakakawaji, T., Higuchi, Y., Ozawa, N., Kurihara, K., et al.: Effect of tribochemical reaction on transfer-film formation by poly (tetrafluoroethylene). J. Phys. Chem. C 118, 11820–11826 (2014)

    Article  Google Scholar 

  20. Bahadur, S., Tabor, D.: The wear of filled polytetrafluoroethylene. Wear 98, 1–13 (1984)

    Article  Google Scholar 

  21. Schwartz, C.J., Bahadur, S.: Studies on the tribological behavior and transfer film–counterface bond strength for polyphenylene sulfide filled with nanoscale alumina particles. Wear 237, 261–273 (2000)

    Article  Google Scholar 

  22. Harris, K.L., Curry, J.F., Pitenis, A.A., Rowe, K.G., Sidebottom, M.A., Sawyer, W.G., et al.: Wear debris mobility, aligned surface roughness, and the low wear behavior of filled polytetrafluoroethylene. Tribol. Lett. 60, 1–8 (2015)

    Article  Google Scholar 

  23. Wieleba, W.: The statistical correlation of the coefficient of friction and wear rate of PTFE composites with steel counterface roughness and hardness. Wear 252, 719–729 (2002)

    Article  Google Scholar 

  24. Franklin, S.E., de Kraker, A.: Investigation of counterface surface topography effects on the wear and transfer behaviour of a POM–20% PTFE composite. Wear 255, 766–773 (2003)

    Article  Google Scholar 

  25. Burris, D.L., Sawyer, W.G.: Improved wear resistance in alumina-PTFE nanocomposites with irregular shaped nanoparticles. Wear 260, 915–918 (2006)

    Article  Google Scholar 

  26. Burris, D.L.: Wear-resistance mechanisms in polytetrafluoroethylene (PTFE) based tribological nanocomposites. University of Florida, Gainesville (2006)

    Google Scholar 

  27. Burris, D.L., Zhao, S., Duncan, R., Lowitz, J., Perry, S.S., Schadler, L.S., et al.: A route to wear resistant PTFE via trace loadings of functionalized nanofillers. Wear 267, 653–660 (2009)

    Article  Google Scholar 

  28. Ye, J., Khare, H.S., Burris, D.L.: Transfer film evolution and its role in promoting ultra-low wear of a PTFE nanocomposite. Wear 297, 1095–1102 (2013)

    Article  Google Scholar 

  29. Ye, J., Khare, H.S., Burris, D.L.: Quantitative characterization of solid lubricant transfer film quality. Wear 316, 133–143 (2014)

    Article  Google Scholar 

  30. Khare, H.S., Moore, A.C., Haidar, D.R., Gong, L., Ye, J., Rabolt, J.F., et al.: Interrelated effects of temperature and environment on wear and tribochemistry of an ultralow wear PTFE composite. J. Phys. Chem. C 119, 16518–16527 (2015)

    Article  Google Scholar 

  31. Pitenis, A.A., Ewin, J.J., Harris, K.L., Sawyer, W.G., Krick, B.A.: In vacuo tribological behavior of polytetrafluoroethylene (PTFE) and alumina nanocomposites: the importance of water for ultralow wear. Tribol. Lett. 53(1), 189–197 (2014)

    Article  Google Scholar 

  32. Krick, B.A., Pitenis, A.A., Harris, K.L., Junk, C.P., Sawyer, W.G., Brown, S.C., et al.: Ultralow wear fluoropolymer composites: nanoscale functionality from microscale fillers. Tribol. Int. 95, 245–255 (2016)

    Article  Google Scholar 

  33. McElwain, S.E., Blanchet, T.A., Schadler, L.S., Sawyer, W.G.: Effect of particle size on the wear resistance of alumina-filled PTFE micro- and nanocomposites. Tribol. Trans. 51, 247–253 (2008)

    Article  Google Scholar 

  34. Burris, D.L., Sawyer, W.G.: Measurement uncertainties in wear rates. Tribol. Lett. 36, 81–87 (2009)

    Article  Google Scholar 

  35. Haidar, D.R., Ye, J., Moore, A.C., Burris, D.L.: Assessing quantitative metrics of transfer film quality as indicators of polymer wear performance. Wear 380–381, 78–85 (2017)

    Article  Google Scholar 

  36. Makinson, K.R., Tabor, D.: Friction and transfer of polytetrafluoroethylene. Nature 201, 464–466 (1964)

    Article  Google Scholar 

  37. Bahadur, S., Gong, D., Anderegg, J.W.: The role of copper compounds as fillers in transfer film formation and wear of nylon. Wear 154, 207–223 (1992)

    Article  Google Scholar 

  38. Bahadur, S.: The development of transfer layers and their role in polymer tribology. Wear 245, 92–99 (2000)

    Article  Google Scholar 

  39. Bahadur, S., Sunkara, C.: Effect of transfer film structure, composition and bonding on the tribological behavior of polyphenylene sulfide filled with nano particles of TiO2, ZnO. CuO and SiC Wear 258, 1411–1421 (2005)

    Article  Google Scholar 

  40. Chang, L., Zhang, Z., Ye, L., Friedrich, K.: Tribological properties of epoxy nanocomposites: III. Charact. Transf Films Wear 262, 699–706 (2007)

    Google Scholar 

  41. Friedrich, K., Flöck, J., Váradi, K., Néder, Z.: Experimental and numerical evaluation of the mechanical properties of compacted wear debris layers formed between composite and steel surfaces in sliding contact. Wear 251, 1202–1212 (2001)

    Article  Google Scholar 

  42. Gong, D., Qunji, X., Hongli, W.: Physical models of adhesive wear of polytetrafluoroethylene and its composites. Wear 147, 9–24 (1991)

    Article  Google Scholar 

  43. McCook, N.L., Burris, D.L., Bourne, G.R., Steffens, J., Hanrahan, J.R., Sawyer, W.G.: Wear resistant solid lubricant coating made from PTFE and epoxy. Tribol. Lett. 18, 119–124 (2005)

    Article  Google Scholar 

Download references

Acknowledgements

The authors are very grateful for the financial support from the National Natural Science Foundation of China (51505117 and 11472096) and the Air Force Office of Scientific Research (FA9550-10-1–0295).

Author information

Author notes

  1. Diana R. Haidar

    Present address: Department of Mechanical Engineering, Carnegie Mellon University, Pittsburgh, PA, USA

Authors and Affiliations

  1. Institute of Tribology, School of Mechanical Engineering, Hefei University of Technology, Hefei, 230009, Anhui, China

    Jiaxin Ye, Bo Tao, Wei Sun & Kun Liu

  2. Department of Mechanical Engineering, University of Delaware, Newark, DE, USA

    Diana R. Haidar, Kazi I. Alam & David L. Burris

Authors
  1. Jiaxin Ye
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Bo Tao
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Wei Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Diana R. Haidar
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Kazi I. Alam
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Kun Liu
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. David L. Burris
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kun Liu.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Ye, J., Tao, B., Sun, W. et al. The Competing Effects of Counterface Peaks and Valleys on the Wear and Transfer of Ultra-Low Wear Alumina–PTFE. Tribol Lett 66, 12 (2018). https://doi.org/10.1007/s11249-017-0966-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • DOI: https://doi.org/10.1007/s11249-017-0966-x

Keywords

Search

Navigation