You are on page 1of 10

Wear 260 (2006) 30–39

Tribological behaviour of epoxy based composites for rapid tooling


Pedro V. Vasconcelos a , F. Jorge Lino b, ∗ , António M. Baptista b , Rui J.L. Neto c
a Departamento de Ciências da Engenharia, ESTG/IPVC, Viana do Castelo, Portugal
b Faculdade de Engenharia da Universidade do Porto, DEMEGI, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal
c INEGI—Instituto de Engenharia Mecânica e Gestão Industrial, Porto, Portugal

Received 2 March 2004; received in revised form 1 November 2004; accepted 23 December 2004
Available online 19 February 2005

Abstract

Epoxy resin composites are frequently applied in moulds manufactured with rapid tooling technologies that are used for wax and polymer
materials injection. With the propose of enlarging the application field of the polymer matrix systems, it is fundamental to select adequate
dispersed phases and analyse their influence on the composite properties in order to reinforce the polymer matrix and tailor the properties
according to the tools specifications.
Thermal conductivity and wear resistance are critical parameters for a good service performance and durability of the mould. Metallic
fillers allow significant improvement in the resin thermal conductivity. In this work, it was possible to show that small amounts of milled
fibres enhance the wear resistance, with little changes in the processability and in the allowed aluminium concentration in the resin matrix.
A tribological study of these materials was performed involving the neat resin, the aluminium filled resin and tri-phase composites composed
by epoxy, aluminium particles and milled glass or carbon fibres. The study was focused on the role of the particles and fibres in the friction
and wear at room temperature and at a typical plastic injection temperature of 160 ◦ C.
© 2005 Elsevier B.V. All rights reserved.

Keywords: Epoxy resins; Composites; Wear; Milled fibres; Rapid tooling

1. Introduction the filling injection stage of abrasive thermoplastic polymers,


making their use in this application not very attractive.
Liquid epoxy resins exhibit a good mixture and processing In this context, a detailed study was conducted to analyse
ability with reinforcement materials in granular or fibre form. the tribological behaviour of these composites, aiming to un-
The result of these mixtures is composite materials with in- derstand the effect of the particle and fibre addition on the
termediate properties depending, however, on the combined epoxy matrix and, consequently, tailor the moulds properties
action of the components. to increase the total number of parts that can be injected.
In rapid prototyping (RP) and rapid tooling (RT) applica-
tions, metallic filled resins are frequently employed in mould
manufacturing for production of small series of plastic parts 2. Materials and experimental work
[1–4].
The injection of fibre reinforced thermoplastic polymers Epoxy resin based composites containing aluminium and
is in a process of great expansion. Moulds manufactured with milled carbon or glass fibres, with the compositions shown
metallic filled polymers [5–7] exhibit limited durability, due in Table 1, were used. The epoxy resin (E) was a commer-
to the extensive wear to which they are submitted during cial tetraepoxide grade based in an aromatic glycidyl amine,
Araldite LY5210 (Vantico, UK) with a high molecular weight
[8–10]. The epoxy resin/curing agent, aluminium powder
∗ Corresponding author. Tel.: +351 225081704/42; fax: +351 225081445. (A–98.7% Al) and fibres (C: carbon fibres; G: glass fibres)
E-mail address: falves@fe.up.pt (F.J. Lino). were manually mixed and cured at room temperature for 48 h

0043-1648/$ – see front matter © 2005 Elsevier B.V. All rights reserved.
doi:10.1016/j.wear.2004.12.030
P.V. Vasconcelos et al. / Wear 260 (2006) 30–39 31

Table 1
Compositions of the tested materials
Designation E EA = E + A EAC = E + A + C EAG = E + A + G
Composition (% in volume) E—100 E—59 E—57.5 E—57.5
A—41 A—38.5 A—38.5
C—4 G—4
E: epoxy; A: aluminium; C: carbon fibres and G: glass fibres.

Fig. 1. Polished surfaces of epoxy resins filled (grey colour) with; (a) aluminium (white particles) and milled glass fibre (dark filaments) – EAG composite;
and (b) aluminium (white particles) and milled carbon fibres (white filaments)—EAC composite.

Table 2
Technical characteristics of the aluminium particles and milled fibres
Dispersed phase Manufacturer Dimensions Sizing
Aluminium powder PD 200 Hexcel (France) 99% < 200 ␮m –
Milled E-glass PPG (USA) 215/11 ␮m (l/d)a Polyvinyl acetate with silane
Milled carbon Toray (Japan) 63/7 ␮m (l/d)a 1 wt% epoxy
a l/d: fibre length/diameter.

and at 40 ◦ C for 14 h, and post-cured at 200 ◦ C for 1.5 h. Fig. 1 at room temperature and at a typical thermoplastics injection
shows micrographs of the polished surfaces of the tri-phase temperature of 160 ◦ C [13]. A comparative study, between
composites after this heat treatment cycle. Aluminium is seen the results obtained with these conventional tests and the
as light grey round particles and glass and carbon fibres as ones using an industrial injection-moulding machine, will
elongated filaments in a grey epoxy matrix. be the subject of other publication.
The technical and mechanical characteristics of the For an extensive wear characterization, two wear tests
raw materials and respective composites are presented in were performed with different typologies and experimental
Tables 2 and 3 [11,12]. conditions (see Fig. 2):
Considering that it is difficult to simulate the erosive wear
mechanisms present in an injection mould, two accessible
tests were employed, which although not reproducing exactly
the mould operation conditions, allow the assessment of the
wear resistance and the integrity of these composites, both

Table 3
Barcol hardness and elastic modulus of the raw materials and respective
composites [11,12]
Materials Hardness Elastic modulus (GPa)
E 40 (Barcol) 2.7
A 58 (Barcol) 69
C 6 (Mohs) [12] 232
G 6.5 (Mohs) [12] 72.5
EA 53 (Barcol) 7
EAC 53 (Barcol) 7.3
EAG 53 (Barcol) 7.3
Fig. 2. Schematic diagram of the wear tests that were employed: (a) metal-
E: epoxy; A: aluminium; C: carbon fibres and G: glass fibres. lographic polishing microabrasion and (b) reciprocating tribometer.
32 P.V. Vasconcelos et al. / Wear 260 (2006) 30–39

- reciprocating tribometer (reciprocating wear type) [14] and conditions. This severe wear is due to the existence of a
- metallographic polishing microabrasion (abrasive wear mixed abrasive/adhesive contact condition [17,18].
type) [15,16].
2.2. Abrasive wear
2.1. Reciprocating wear
This test was employed to determine the materials spe-
In the reciprocating test, a flat surface of the sample cific wear rate at room temperature and was only used to
is abraded against a steel sphere, involving sliding fric- complement the information given by the reciprocating test.
tion and wear at high pressure, giving information of the In each wear cycle of the metallographic polishing mi-
material integrity level. This tribological configuration de- croabrasion test, three rectangular prismatic samples were
creases the tendency for the topography modification effect simultaneously abraded against a SiC paper to assess the
caused by polymer transfer, keeping the contact nature of the abrasive wear resistance. The samples were cut in rectangu-
steel–polymer interface almost unchanged during the whole lar prisms of 30 mm length with a square section of 10 mm.
test. Prior to the test, the specimens were polished with a P1200
To determine the influence of the temperature on the fric- SiC paper and weighed before being mounted into the spec-
tion and wear behaviour (dry conditions), a reciprocating tri- imen holder. The three specimens were separated from each
bometer, Cameron Plint TE67 (Budenberg, UK) was used. other in the holder by 120◦ . The wear apparatus was a semi-
The following test conditions were established: automatic grinding–polishing machine (Planopol-3, Struers,
Denmark), where a constant load of 60 N was applied for
pin—polished steel sphere (DIN-105Cr6) with 9.5 mm di-
2 min. The mean velocity of the specimens, mounted into the
ameter;
sample holder, relatively to the abrasive disk (P320 SiC pa-
specimen—rectangular plate (dimensions: 60 mm × 40 mm
per), was 202.5 m/min. Water was used as lubricant with a
× 5 mm);
constant 250 ml/min delivering rate. The sample holder and
force = 25.4 N (pressure ≈ 25 MPa);
the disk rotate off-axis, which allows the samples to sweep
amplitude motion = 10 mm;
a wide working area, keeping the wear rate practically un-
maximum linear velocity = 0.13 m/s;
changed during the test [14].
sliding distance = 82 m.
The mass loss was measured weighing the specimen be-
Three samples were used for each material and tempera- fore and after the test and the specific wear rate, Ws , was
ture (room temperature and 160 ◦ C). Due to the presence of calculated by [19]:
defects, such as scratches and cavities that can significantly m
influence the test results, the sample surfaces were polished Ws = , (1)
lρF
with a P1200 SiC paper.
The volume of the material removed during the wear test where m is the mass loss, l the sliding distance, ρ the density
was determined by contact profilometry (Hommel Werke LV- of the specimen and F is the normal load.
50, Hommel Werke-Thyssen, Germany). This volume was Six wear cycles were performed with each material.
computed by multiplying the medium area of three wear track
sections by the respective track length.
For comparison analysis, the parameters of the test condi- 3. Results and discussion
tions of the two wear tests are indicated in Table 4.
The worn surfaces of the specimens were examined in a 3.1. Reciprocating wear
scanning electron microscope (Jeol JSM-6301F, USA) and
the chemical X-rays spectra (SEM/EDS) obtained. 3.1.1. Friction behaviour
The reciprocating test allowed the determination of Initially, at room temperature (see Fig. 3a), the neat epoxy
the wear coefficient evolution relatively to the sliding resin exhibits a constant friction coefficient, µ, of about 0.16.
distance and the effect of the temperature on the tribological Nevertheless, after about 30 m of sliding distance, µ begins
behaviour of the different composite materials, considering to increase at a slow rate. This behaviour is probably due to
the neat resin as a reference. It was possible to apply the thermal softening of the resin, as a result of the pressure
a significantly higher pressure in dry conditions, which and heat generated on the reduced contact area. Increasing the
also allowed the material integrity evaluation under severe sliding distance, the sphere penetrates more deeply into the

Table 4
Parameters employed in the two wear tests: metallographic polishing microabrasion and reciprocating tribometer
Wear test Counterface material Lubricant Pressure (MPa)a Velocitya (m/min) Time (min) Temperature (◦ C)
Metallographic polishing microabrasion P320 SiC paper Water 0.6 202.5 2 RT
Reciprocating tribometer Steel sphere d = 9.5 mm – 25 5.1 16 RT 160 ◦ C
a Mean values.
P.V. Vasconcelos et al. / Wear 260 (2006) 30–39 33

epoxy surface, increasing the ploughing deformation zone respective instability are also detected and a slightly higher
and the real contact area and consequently raising the fric- steady state friction coefficient. At the end of the wear test,
tional force [19]. this value increases by 12% in EAC composites and about
When the temperature rises to 160 ◦ C, the neat resin be- 9% in EAG composites, relatively to the similar material at
haviour is significantly affected. The initial friction coeffi- room temperature.
cient increases abruptly, and after about 20 m stabilizes to a
magnitude of about 0.65. After this period, the curve tends to 3.1.2. Wear and topography of worn surfaces
reach a steady state. At this high temperature, the thermally (reciprocating tribometer)
affected resin layer increases rapidly producing a larger real Compared with the composites, the neat resin specific
contact area and high friction coefficients. The short-term wear rate is reduced, showing that the friction energy is dissi-
fluctuations that are present at room temperature are similar pated in the deformation and in the heating up of the plough-
at high temperature. ing zone (Table 5). The spectra of characteristic X-rays (EDS)
The addition of aluminium particles to the epoxy system of the worn surfaces shows the presence of a significant iron
improves the material stiffness and thermal conductivity by concentration that is visible in the SEM images as a light grey
one order of magnitude [11,20]. The better thermal conduc- region (Fig. 4). The steel sphere suffers wear and incorporates
tivity contributes to a more efficient dissipation of the heat iron particles in the interfacial layer. Due to the test condi-
generated on the contact area. Due to the presence of alu- tions, these iron particles are certainly oxidised. SEM image
minium, the friction coefficient (µ) exhibits initial peaks for shows multiple parallel microcracks, approximately perpen-
µ = 0.5. The initial stage is characterised by a high friction dicular to the sliding direction (vertical direction), indicating
coefficient (tending to decrease with the distance) and irreg- the presence of a fatigue mechanism (Fig. 4a) [21]. Table 5
ular fluctuations, showing an unstable frictional behaviour shows that, at 160 ◦ C, the wear rate increases significantly.
(Fig. 3b). After 20 m of sliding distance, a steady state is The highest wear, 99.8 × 10−5 mm3 /Nm (Table 5), was
reached. obtained in aluminium filled epoxy with a large production
At 160 ◦ C, the behaviour is similar, but a slight increase of debris derived from the particle pullout during the test.
in µ was detected after 20 m of sliding distance. This is due to the decrease of the material integrity, where
The incorporation of glass or carbon fibres to the previous the cohesion now depends basically on the aluminium/resin
material keeps the friction coefficient practically unchanged interface resistance. Wear track micrographs and EDS anal-
(Fig. 3c and d). At room temperature, the initial highly unsta- ysis show an aluminium loss. In the SEM image of Fig. 5a,
ble frictional behaviour disappears after a short sliding dis- a large plastic deformation of the aluminium particles is ob-
tance. Both glass and carbon composites show similar friction served in the wear surface, masking the real aluminium loss.
behaviour with a slightly higher friction coefficient observed The approximately equiaxial aluminium particle geometry
in the glass fibre composite. At 160 ◦ C, the initial peak and the and its chemical nature produce a relatively poor adhesion

Fig. 3. Friction coefficient (µ) as a function of the sliding distance, at room temperature and at 160 ◦ C for: (a) the neat epoxy; (b) aluminium filled epoxy; (c)
glass fibre reinforced EAG composite and (d) carbon fibre reinforced EAC composite.
34 P.V. Vasconcelos et al. / Wear 260 (2006) 30–39

Table 5
Comparison of the specific wear rate results of epoxy (E), epoxy with aluminium (EA) and epoxy with aluminium and fibres (EAG and EAC) systems, at room
temperature and at 160 ◦ C, determined in the reciprocating tribometer
Materials Specific wear rate (10−5 mm3 /Nm) Percentage increase rate (RT → 160 ◦ C)

RT 160 ◦ C

Mean value Standard deviation Mean value Standard deviation


E 1.82 0.22 4.6 0.23 155
EA 15.5 1.68 99.8 5.42 544
EAG 7.39 0.31 19.1 0.31 158
EAC 8.18 0.57 25.7 0.78 214

force to the epoxy matrix, as suggested in references [22] and The high aluminium thermal conductivity and fibre stiffness,
[23]. This fact is responsible for the easy aluminium pull out combined with the good adhesive bonding between fibres
under the high contact pressure of the pin. Furthermore, the and epoxy resin, substantially enhances the tribological be-
aluminium particles are significantly harder than the epoxy haviour of the respective composites.
resin (see Table 3), which means that when released from EDS analysis of the final wear track reveals loss of alu-
the composite, they can also act as hard third-body abrasives, minium and resin and fibres enrichment relatively to the origi-
increasing the composite wear rate [24]. This effect would nal material. The combination of these materials significantly
be enhanced by the probable oxidation of the aluminium into improves the wear resistance.
alumina. Fig. 5b shows microcracks that are now concen- At room temperature, the wear resistance of the carbon
trated in the particle/resin interface, contributing to the alu- and glass fibre composites is very similar, but at 160 ◦ C, the
minium particles debonding. No iron traces were detected in wear rate of the carbon fibre composite experiments a 214%
the composite. Fig. 6 shows that the wear tracks are different increase, while the glass fibre composite only undergoes a
in the initial and final stage of the wear test. It is observed 158% increase (Table 5). These particular changes of the tri-
that in the initial stage, the surface is more wrinkled, prob- bological behaviour, due to the thermal effect, can be ex-
ably due to the severe wear conditions originated by higher plained if one considers, as described below, the fibre and
aluminium concentration in the wear track. matrix properties.
When the temperature rises to 160 ◦ C, the wear rate in- Glass fibres display a homogeneous, amorphous and
creases about 544% for the selected sliding distance (Table 5). isotropic microstructure. On the other hand, PAN carbon
Similarly to what occurred with the abrasive wear test, fibres are composed by a heterogeneous stacking of fine
in the reciprocating test the fibre addition to the aluminium crystalline layers of aromatic type (nanometric width) [25].
filled epoxy also significantly improves the composite wear This intrinsic heterogeneity originates anisotropic thermal
resistance. These tri-phase composites show more integrity, properties, such as thermal conductivity and coefficient
despite the low fibres concentrations that were employed. of thermal expansion, CTE. The latter varies from −0.6

Fig. 4. SEM images of the wear track on the neat resin, at room temperature: (a) the light grey contours that surround the microcracks reveal the existence of
iron (secondary electrons, SE) and (b) the iron distribution is clearly detected, composing a fine lace with a good contrast (backscattered electrons, BE).
P.V. Vasconcelos et al. / Wear 260 (2006) 30–39 35

Fig. 5. SEM image of the aluminium filled epoxy: (a) on the left side, the surface before wearing, and, on the right side, plastic deformation of the aluminium
particles mask the metallic particles depletion, after wearing (BE) and (b) with high magnification it is possible to see that the microcracks contribute to the
aluminium particles debonding (SE).

to +10 × 10−6 ◦ C−1 on the longitudinal and transversal SEM images show an extensive carbon fibre fragmentation
direction, respectively. Aluminium and glass fibres also (Fig. 7). The wear track profile of the EAC composite is
exhibit low CTE, 23 × 10−6 ◦ C−1 and 5 × 10−6 ◦ C−1 , re- more irregular than in the EAG composite, which probably
spectively, while the epoxy resin shows a much higher value, indicates that its surface is prone to suffer more damage and
66 × 10−6 ◦ C−1 [11,26]. Epoxy composites, during the cure a more severe wear (Fig. 8).
at 200 ◦ C and under normal working conditions, are subjected Fig. 9 shows SEM images of the worn track of the EAG
to different temperatures. These temperature fluctuations composite. In the initial wearing stage, an interface layer with
promote CTE mismatches between the dispersed phases and a viscous mixture of resin and fine aluminium debris is ob-
the epoxy resin, leading to differential thermal stresses that served. At the end of the test, the wear track exhibits lower
can contribute to the degradation of the interface quality aluminium content, resulting in higher resin and glass fibre
[27]. concentrations.
Due to the longer friction action of the composite, the alu-
minium particles suffer a severe plastic deformation before
its removal (Fig. 10). Some fragmented fibres appear stacked
to the aluminium particles.
At high temperature, the EAC composites exhibit lower
wear resistance than the EAG composites. This can be ex-
plained by the fact that carbon fibres are more fragmented,
and probably more easily removed from the wear track, than
the glass fibres, which are less brittle than carbon fibres [28].
The influence of the temperature on the mechanical be-
haviour of the epoxy-based materials was examined by dy-
namic mechanical thermoanalysis (DMTA) (Fig. 11). The
results obtained show that, at 160 ◦ C, the neat resin and the
aluminium filled epoxy (EA) experiment a remarkable loss
in their mechanical properties. The tan δ curve, at 160 ◦ C,
demonstrates that the epoxy systems are close to the glass
transition temperature, detected at about 200 ◦ C. EAC and
EAG composites show DMTA behaviour similar to the EA
composites.
The decrease of the matrix modulus with the temperature
Fig. 6. SEM images of the worn track of the EA composite. The left side affects the fibre–matrix interfacial shear strength, as predicted
shows the track in the initial wear stage (the surface is wrinkled due to the
pull out of the aluminium particles), the right side shows the wear track in
by Cox and Cooke theory [29,30] and experimentally demon-
the final stage of the test. The asperities are now smaller (SE). strated by Rao and Drzal [31]. These researchers proved that
36 P.V. Vasconcelos et al. / Wear 260 (2006) 30–39

Fig. 7. SEM images of the wear track of the EAC composite at 160 ◦ C: (a) the aluminium loss in the wear track (at the left side) is clearly visible (BE) and (b)
the wear track shows deformed aluminium particles and fragmented carbon fibres (BE).

Fig. 8. Cross section of the wear track profile of: (a) carbon fibre composite, EAC and (b) glass fibre composite, EAG. The surface topography of the two
composites, before and after wearing, is different, despite the same processing, surface finishing and wear conditions.

Fig. 9. SEM images of the worn track of the EAG composite: (a) on the left side, the wear track in the initial stage of the test (an interface layer with resin and
fine aluminium debris is produced) and (b) on the right side, the wear track at the end of the test.
P.V. Vasconcelos et al. / Wear 260 (2006) 30–39 37

Fig. 10. SEM images of the wear track of the composites at 160 ◦ C showing the aluminium particles with severe plastic deformation: (a) EAG, epoxy resin
(black), oxidised aluminium (grey), glass fibre (white) (BE) and (b) EAC, epoxy and carbon fibres (grey), aluminium (white) (BE).

Fig. 11. Neat resin (E) and aluminium filled epoxy (EA) DMTA (dynamic mechanical thermoanalysis) results: (a) elastic modulus and (b) tan δ.

the fibre–matrix interfacial shear strength (determined by the When compared with the E neat resin, the aluminium ad-
fragmentation analysis), decreases nonlinearly with the ma- dition to the resin yields about 25% decrease in Ws , as shown
trix modulus. Considering this, the modulus decrease at high in Fig. 12.
temperatures produces a softening effect, negatively influ- As it was expected [18,32], adding reinforcement ele-
encing the matrix and interface properties, and consequently ments, like milled carbon and glass fibres (EAC and EAG
causing the weak tribological performance of all the studied
materials.

3.2. Abrasive wear

The SiC particles of the abrasive paper act as multiple


microtools that wear the material to be tested. This abrasive
wear depends on the hardness of the two contacting materials,
cutting properties of the hard particles and microcracking
resistance of the softer material [17]. The test was performed
at low pressure and water lubricated to avoid vibrations and Fig. 12. Specific wear rate in monolithic and composite resins with different
excessive heating. formulations, obtained in the abrasive wear test.
38 P.V. Vasconcelos et al. / Wear 260 (2006) 30–39

composites), enhances the wear resistance, reducing the Ws Acknowledgements


by 52 and 56%, respectively, relatively to the neat resin
(Fig. 12). Financial support from FEDER through the Project
POCTI/EME/41199/2001, “Development of an Indirect
Rapid Tooling Process Based in Polymeric Matrix Compos-
4. Concluding remarks ites”, approved by the Fundação para a Ciência e Tecnologia
(FCT) and POCTI.
Mixtures of fibres and aluminium particles can be used Partly funded by European Social Fund, public contest
to optimise mechanical and thermal properties of compos- 4/5.3/PRODEP/2000, submitted by Escola Superior de Tec-
ites manufactured for rapid tooling applications. These type nologia e Gestão of Instituto Politécnico de Viana do Castelo.
of tools, although less demanding in terms of technologi-
cal requirements than the conventional tools, can exhibit an
adequate performance in applications where a short number References
of parts is required, with the enormous advantage of being
obtained in a short period of time. [1] P. Vasconcelos, F. Jorge Lino, Rui J. Neto, The importance of rapid
The neat epoxy resin in the reciprocating test exhibits the tooling in product development, Mater. Sci. Forum (2002) 169–172.
lowest wear. SEM images show that the main mechanism [2] P. Vasconcelos, F. Jorge Lino, Rui J. Neto, O fabrico rápido de
for energy dissipation is located at the interface layer of the ferramentas ao serviço da engenharia concorrente, Tecnometal 136
(2001) 17–21.
wear track, involving adhesion contact, plastic deformation, [3] F. Jorge Lino, F. Braga, M. Simão, Rui J. Neto, T.P. Duarte,
microcracking and iron transfer. These mechanisms also con- Protoclick—Prototipagem Rápida, Protoclick, Porto, Portugal, 2001.
tribute to the constant increase of the friction coefficient with [4] C.K. Chua, K.F. Leong, C.S. Lim, Rapid Manufacturing: Principles
the sliding distance. and Applications, World Scientific Publishing Co. Pte Ltd., 2003.
Due to geometric relations and surface chemistry, the fi- [5] S.K. Bhattacharya, Metal-Filled Polymers, Marcel Dekker Inc., USA,
1986.
bres tend to adhere more strongly to the resin matrix than [6] U. Baraldi, C. Emmerchts, Low cost tooling for injection moulding,
aluminium particles. Submitted to the high pressure of the in: Proceedings of Composites Tooling III, Elsevier Science Ltd.,
pin, the aluminium particles are easily removed, while the 1994, pp. 27–42.
fibres, staying longer in the tri-phase composite, increase [7] P. Vasconcelos, F. Jorge Lino, R.J. Neto, Fabrico rápido de ferra-
considerably the load carrying capacity, reducing the friction mentas utilizando resinas carregadas, in: Proceedings of 1as Jornadas
Politécnicas de Engenharia Mecânica, Leiria, Portugal, 2001.
coefficient, and consequently the composite wear rate. [8] L. Matejka, K. Dusek, Mechanism and kinetics of curing epoxides
High temperatures affect the mechanical properties of the based on diglycidylamine with aromatic amines. 1. The reaction of
composite, due to resin softening and reduction of the particle diglycidylaniline with secondary amines, Macromolecules 22 (1989)
and fibre/matrix adhesion. 2902–2911.
In the reciprocating test, EAG glass reinforced compos- [9] L. Matejka, Amine cured epoxide networks: formation, structure and
properties, Macromolecules 33 (2000) 3611–3619.
ites show lower wear rate than the EAC carbon reinforced [10] B.A. Rozenberg, Kinetics, thermodynamics and mechanism of reac-
composites, and a better tribological behaviour, especially at tions of epoxy oligomers with amines, Adv. Polym. Sci. 75 (1986)
high temperature (160 ◦ C). Besides the high stiffness of the 113–165.
carbon fibres, their brittle nature makes them more prone to [11] P. Vasconcelos, Fabrico rápido indirecto de ferramentas compósitas
a partir de modelos de prototipagem rápida, PhD Thesis, Faculdade
break under severe wear conditions than the glass fibres.
de Engenharia da Universidade do Porto, Porto, Portugal, October
Considering the hardness and stiffness of the raw materi- 2004.
als used in the composites, they can be sorted, from the low- [12] G.C. Rosa, I.J.R. Baumvol, Tribology of polymer composites used
est to the highest value, in the following sequence: epoxy, as frictional materials, in: K. Friedrich (Ed.), Advances in Composite
aluminium, carbon and glass fibres. In general, softer mate- Tribology, Elsevier, 1993, pp. 583–626.
[13] G. Mennig, Wear in Plastics Processing, Hanser Publishers, 1995.
rials are more abraded than the harder and stiffer ones. The
[14] A. Schelling, H.H. Kausch, Reciprocating dry friction and wear of
abrasive wear behaviour, determined by the metallographic short fibre reinforced polymer composites, in: K. Friedrich (Ed.),
polishing microabrasion test, has shown that this also hap- Advances in Composite Tribology, Elsevier, 1993, pp. 65–105.
pens with composite materials, since the interface adhesion [15] J. Hawk, Abrasive wear testing, in: Mechanical Testing and Evalu-
resistance between the reinforcing dispersed phase and the ation ASM Handbook, vol. 8, 2000, pp. 325–337.
[16] T. Yamamoto, T. Olsson, M.E. Hogmark, Three body abrasive wear
resin matrix can withstand the tangential cutting force of the
of ceramic materials, Wear 174 (1994) 21–31.
abrasive. For this reason, the studied materials exhibited the [17] J.F. Archard, Contact and rubbing of flat surfaces, J. Appl. Phys. 24
following order, from the lowest to the highest wear resis- (8) (1953) 981–988.
tance: E, EA, EAC and EAG. [18] K. Friedrich, Wear of reinforced polymers by different abrasive coun-
The milled glass fibres, used in aluminium filled epox- terparts, in: K. Friedrich (Ed.), Friction and Wear of Polymer Com-
posites, Elsevier, Amesterdam, 1986, pp. 233–287.
ies, increase the integrity of the composite material, both at
[19] A.M. Hagger, M. Davis, Short fibre reinforced, high-temperature
room and high temperature. They are expected to improve resistant polymers for a wide field of tribological applications, in:
the erosive wear resistance of the mould during the injection K. Friedrich (Ed.), Advances in Composite Tribology, Elsevier, 1993,
stage. pp. 107–157.
P.V. Vasconcelos et al. / Wear 260 (2006) 30–39 39

[20] P. Vasconcelos, F. Jorge Lino, R.J. Neto, Utilização de fibras moı́das [27] P.A. Smith, Carbon fibre reinforced plastics-properties, in: A. Kelly,
no fabrico de ferramentas de matriz polimérica, in: Proceedings of C. Zweben (Eds.-in-chief), R. Talreja, J.-A. Manson (Vol. Ed.), Com-
2as Jornadas Politécnicas de Engenharia Mecânica, Setúbal, Portugal, prehensive Composite Materials, vol. 2, Polymer Matrix Composites,
2001. Elsevier, 2000, pp. 107–150.
[21] N.P. Suh, Tribophysics, Prentice Hall, Englewood Cliffs, NJ, 1986. [28] I. Narisawa, High-speed tribology of polymer composites, in: K.
[22] M.G. Barthés-Labrousse, Adhesion mechanisms at amine-cured Friedrich (Ed.), Advances in Composite Tribology, Elsevier, 1993,
epoxy/aluminium interfaces, J. Adhes. 57 (1996) 65–75. pp. 559–582.
[23] J. Marsh, L. Minel, M.G. Barthés-Labrousse, D. Gorse, Interaction [29] H.L. Cox, The elasticity and strength of paper and other fibrous
of epoxy model molecules with aluminium, anodised titanium and materials, Br. J. Appl. Phys. 3 (1952) 72–79.
copper surfaces: an XPS study, Appl. Surf. Sci. 133 (1998) 270–286. [30] T.F. Cooke, High peformance fibre composites with special emphasis
[24] M. Godet, The third-body approach. A mechanical view of wear, on the interface—a review of the literature, J. Polym. Eng. 7 (3)
Wear 100 (1984) 437–453. (1987) 197–254.
[25] S. Bennett, D. Johnson, Interfacial debonding and fiber pull-out [31] V. Rao, L.T. Drzal, Review of methods for characterization of in-
stresses of fiber-reinforced composites, J. Mater. Sci. 18 (1983) terfacial fiber–matrix interactions, Polym. Compos. 12 (1) (1991)
3337–3347. 48–56.
[26] W. Callister, Materials Science and Engineering, John Willy & Sons [32] J.K. Lancaster, The effect of carbon fibre reinforcement on the fric-
Inc., 2000. tion and wear of polymers, Br. J. Appl. Phys. 1 (2) (1968) 549–559.

You might also like