MECHANICAL PROPERTIES &

DRY SLIDDING WEAR BEHAVIOUR OF

GRAPHITE FILLER REINFORCED
EPOXY COMPOSITES

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3. OBJECTIVES OF THE WORK:

 Conducting literature survey

 Fabrication & processing of epoxy resin composites

 Conducting density test and hardness test on the specimens

 Studies on Dry sliding wear behaviour of the composite

specimens using pin-on-disc machine.

 Worn surface analysis using SEM

 Analysis of the experimental results

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1. INTRODUCTION TO COMPOSITES
 Composites:
- Mixture or combination of diff. materials
- Mainly made of matrix and reinforcement

 Types of composites with respect to matrix

- Polymer Matrix Composites [PMCs]
- Metal Matrix Composites [MMCs]
- Ceramic Matrix Composites [CMCs]

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POLYMER MATRIX COMPOSITES
 Most widely used , also known as FRPs
 Mainly of two kinds: thermosets and thermoplastics
 Polymers are ideal material as they are light weight
 Abrasion and chemical resistant
 Can be processed easily and posses desirable mechanical
properties
 Uses polymer base resin as matrix and fibers such as
glass, carbon as reinforcement
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 Thermosets

Phenolic
Epoxy polyester
polyamide resins

Thermoset materials
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EPOXY:
 Low molecular weight pre-polymers or higher
molecular weight polymer
 Easy to process
 Contains at-least two epoxide group
 Rarely exists as pure substances
 High hot and wet strength properties
 Good mechanical properties
 Used in aerospace and defense applications
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 GRAPHITE
 Soft allotrope of carbon – Solid lubricant

 The crystal lattice of graphite consists of hexagonal rings

 Each carbon atom is covalently bonded to three other atoms in the

plate

 Bonded to each other by weak Van der Waals forces

 Low shear strength and high compression strength

 Graphite forms a lubrication film strongly adhered to the substrate

surface
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 2. LITERATURE SURVEY

 B Suresha [1], made investigations on the dry sliding wear & two-body
abrasive wear behavior of graphite filled carbon fabric reinforced epoxy
composites. Excellent wear characteristics were obtained with carbon-
epoxy containing graphite as filler especially with carbon-epoxy
containing 10 wt% graphite as filler.

 K. M. Subbaya [2], made investigations on the Three-Body Abrasive

Wear Behavior of Graphite Filled Carbon-Epoxy Composites Using
Grey-Based Taguchi Approach. The results show that the addition of
graphite particles into Carbon-Epoxy composite increased the wear
resistance considerably.

 B Suresha [3], made investigations on influence of graphite filler on

two-body abrasive wear behavior of carbon fabric reinforced epoxy
composites. Graphite filler in carbon-epoxy reduced the specific wear
rate. Further, the wear volume loss drops significantly with increase in
graphite content.
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 Subita Bhagat [4], made study on effect of graphite filler on
Mechanical behavior of Epoxy composite which is prepared by
compression molding machine. The obtained material has increased
tensile strength property, break decreases slowly as filler
concentration increases due stiffness increases with filler content,
flexural strength increases of graphite content.

 B.Suresha [5], here glass epoxy composite is used instead of epoxy.

In his studies he had made three composite, they are glass epoxy
with graphite, glass epoxy with silicon carbide(SiC), only just glass
epoxy. Results shows graphite contribute in reducing friction and
exhibited better wear resistant properties.

 B.Suresha [6], made study on Mechanical and Tribological

Properties of Glass–Epoxy composites with and without Graphite
particulate filler. While testing for mechanical properties it was
found that increase in tensile strength , tensile modulus but decrease
in percentage elongation with increase in graphite filler. 9
 M. Sudheer [7], done research to investigate the influence of graphite
fillers on the dry sliding wear and abrasive wear behavior of carbon
fabric reinforced epoxy composites. Wear behavior of 10 wt%
graphite filled carbon epoxy composites are better compared to
unfilled and lower graphite filled carbon fiber reinforced epoxy
composites.

 K. Kumaresan [8], made research on carbon fabric reinforced epoxy

composites with and without silicon carbide filler for the dry sliding
wear test conditions which include different applied load sliding
velocity. Results showed that the surface hardness value of the SiC
filled C-E composite is slightly higher than the unfilled composite.

 Xiubing Li [9], made research on wear test of epoxy composites

specimens paired with A36 steel specimen under air lubricated
condition were carried out on a ring block wear tester typed M200.
Results showed that as graphite content increasing, the wear volume
decreases sharply first, then slightly goes up when graphite content is
30% volume.
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 H. Ranganna [10], made study on the development and
mechanical behavior of graphite/ granite filled epoxy hybrid
composites. It was also found that the tensile strength were
slightly higher for the composites having graphite as material.
The impact fracture surfaces were later scanned using scanning
electron microscopy.

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FABRICATION PROCESSES FOR COMPOSITES
 Open mould process
-Hand lay up process
-Spray lay up process
-Vacuum bag moulding
-Filament winding process

 Closed moulding process

-Pultrusion process
-Compression moulding
-Resin transfer moulding
-Injection moulding
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SPIT DIE COMPRESSION MOULDING

• Weight amount of polymer and is placed in lower half

mould

• The upper half of is moves downwards, pressing on 13

polymer charge and forcing it to fill the mould cavity .

MATERILAS FOR SPECIMEN FABRICATION

 Epoxy resin (LY556+HY951) as host matrix materials

 Graphite filler (less than 100 micron meter)

as reinforcement material

 Hardener used for LY556 epoxy resin is Aradur

HY951

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 Details of samples prepared
Sample Wt. % of
Matrix Filler
Code Filler

C1 Epoxy ------- ------

C2 Epoxy Graphite 10

C3 Epoxy Graphite 20

C4 Epoxy Graphite 30

C5 Epoxy Graphite 40
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 Standards used in specimen testing

ASTM Standards Properties to be tested

Hardness (Rockwell M Scale)

ASTM D785
(specimen size 10x10x3mm)

Dry sliding wear

ASTM G99-05
(specimen size 10x10x3mm)

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 TESTING DETAILS
 Density test
 Rockwell hardness test

 Dry sliding wear behaviour on Pin-on-disc machine

 Worn surface analogy using SEM

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PIN-ON-DISC MACHINE
 It is a quick and easy method of kinetic friction and
sliding wear measurement

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 RESULTS AND DISCUSSION
Effect of graphite filler content on density of composites
Sample Density (g/cc)
C0 1.15
C10 1.302
C20 1.374
C30 1.401
C40 1.434
Density (g/cc)
1.5

1.4
Density (g/cc)

1.3

1.2

1.1
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C0 C 10 C 20 C 30 C 40
% of Filler Content
Effect of graphite content on the hardness of neat epoxy
Hardness
Sample
(Rockwell M scale)
C0 52
C 10 53
C 20 55
C 30 56
C 40 64
Rockwell Hardness (M scale)

65

60
RHN

55

50

45
C0 C 10 C 20 C 30 C 40 20
Sample
 (a) speed 3m/s

0.45

0.4

0.35
COF

10N
0.3
20N

0.25

0.2
C0 C 10 C 20 C 30 C 40
% of Filler Content

Coefficient of friction as a function of filler content for 3m/sec

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Coefficient of friction of different samples for
speed 3m/s and 5m/s
Coefficient of friction
Sample Load (N)
3 m/s 5 m/s
10 0.443 0.356
C0
20 0.314 0.345
10 0.375 0.288
C 10
20 0.283 0.281
10 0.313 0.261
C 20
20 0.271 0.256
10 0.256 0.241
C 30
20 0.225 0.229
10 0.234 0.225 22
C 40
20 0.228 0.215
Coefficient of friction as a function of filler content for 3m/sec

(a) speed 3m/s

0.45

0.4

0.35
COF

10N
0.3
20N2

0.25

0.2
C0 C 10 C 20 C 30 C 40
% of Filler Content
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Coefficient of friction as a function of filler content for 5m/sec

(b) speed 5m/s

0.45

0.4

0.35
COF

0.3
10N
0.25 20N

0.2

0.15
C0 C 10 C 20 C 30 C 40
% of Filler Content

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 Specific wear rate of different samples for
different speeds samples for speed 3m/s and 5m/s
Specific wear rate, Ks×10-6
Sample Load (N) (mm3/Nm)
3m/s 5m/s
10 36.23 30.42
C0
20 24.63 14.53
10 5.12 7.29
C 10
20 3.64 3.84
10 4.86 7.13
C 20
20 2.86 3.64
10 4.75 6.98
C 30
20 2.37 2.37
25
10 4.64 5.12
C 40
20 2.32 2.32
Specific wear rate as a function of filler content for 3m/s

(a) speed 3m/s

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SPECIFIC WEAR RATE, Ks×10-6

35
30
25
(mm3/Nm)

20
10N
15 20N
10
5
0
C1 C2 C3 C4 C5
COMPOSITE SAMPLES
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Specific wear rate as a function of filler content for 5m/s

(b) speed 5m/s

SPECIFIC WEAR RATE, Ks×10-6

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(mm3/Nm)

30

25

20

10N
15
20N

10

0
C1 C2 C3 C4 C5

COMPOSITE SAMPLES

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SEM images of worn surface of different percentage of graphite
filled epoxy sample under 20N and at speed 5m/s

C0 C10

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 SEM images of worn surface of different percentage of
graphite filled epoxy sample under 20N and at speed 5m/s

C20 C30

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 SEM images of worn surface of different percentage of
graphite filled epoxy sample under 20N and at speed 5m/s

C40

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 CONCLUSION
Graphite can improve density, hardness and dry sliding wear
properties of neat epoxy.

Increase in the graphite content increases the hardness of

polymer composites.

Increase in the graphite content increases the wear resistance of

the polymer composites.

Performance of graphite filled epoxy composites is found better

than unfilled epoxy composites.

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 SCOPE FOR FUTURE WORK

•The studies can be made by varying the filler material size (other
than 100µm) with the base matrix.

•Effect of graphite filler on a different matrix (other than epoxy)

can be studied.

•FEM analysis can be carried out in order to study the mechanical

properties of composite specimens.

•A study on other forms of wear can be carried out in order to study

the tribological behaviour of specimens.

•The studies can be made for higher load (more than 20N) and
higher speed (above 5m/sec). 32
 REFERENCES
1. B Suresha, Siddaramaiah, Kishore, S. Seetharamu, P. Sampath
Kumaran, “Investigations on the influence of graphite filler
on dry sliding wear and abrasive wear behaviour of carbon fabric
reinforced epoxy composites” Wear, September 2009; Vol. 267(9-
10), pp. 1405-1414.

2. K. M. Subbaya, N. Rajendra, Y. S. Varadarajan, B. Suresha,

“Multiple Response Optimization of Three-Body Abrasive Wear
Behaviour of Graphite Filled Carbon-Epoxy Composites Using
Grey-Based Taguchi Approach” Journal of Minerals and Materials
Characterization and Engineering, 2012, pp. 876-884.

3. B. Suresha, B.N. Ramesh, K.M. Subbaya, B.N. Ravi Kumar, G.

Chandramohan “Influence of graphite filler on two-body abrasive
wear behaviour of carbon fabric reinforced epoxy composites”,
Materials and Design, April 2010; Vol. 31(4): pp. 1833-2000.

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4) Subita Bhagat, Pardeep Kumar Verma , “Effect of Graphite
Filler on Mechanical Behaviour of Epoxy Composites”,
International Journal of Emerging Technology and Advanced
Engineering, Volume 3, Issue 2, February 2013, ISSN 2250-
2459.

5) B.Suresha, G.Chandramohan, J.N Prakash, V. Balusamya

and K.sankaranarayasamy, “The Role of Fillers on Friction
and Slide Wear Characteristics in Glass-Epoxy Composite
Systems”, Journal of Minerals and Materials Characterization
and Engineering, Nov 2006, Vol. 5(1), pp. 87-101.

6) B.Suresha, G. Chandramohan, N. M. Renukappa,

Siddaramaiah, “Mechanical and Tribological Properties of
Glass–Epoxy Composites with and Without Graphite
Particulate Filler”, Journal of Applied Polymer Science,
Volume 103 (4), February 2007, pp. 2472-2480.
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7. M. Sudheer, K. Hemanth, K. Raju, Thirumaleshwara Bhat,
“Enhanced Mechanical and Wear Performance of Epoxy/glass
Composites with PTW/Graphite Hybrid Fillers”, 3rd
International Conference on Materials Processing and
Characterization, pp. 975 – 987, 2014.

8. K. Kumaresan, G. Chandramohan, M. Senthilkumar, B.

Suresha, S. Indran, “Dry Sliding Wear Behaviour of Carbon
Fabric-Reinforced Epoxy Composite with and without Silicon
Carbide”, Composite Interfaces, 18 (2011), pp. 509–526.

9. Xiubing Li, Yimin Gao, Jiandong Xing, Yu Wang, Liang

Fang, “Wear reduction mechanism of graphite and MoS2 in
epoxy composites”, School of Material Science and
Engineering, Xian Jiaotong University, Xian 710049, PR
China, 2004, pp. 279–283.
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10. H. Ranganna, M. Ashok Kumar, A. Ramesh, N. Madhuva
Reddy, N. karthikeyan, V. Nikil Murthy, S. Raja Kumar, S.
Mahboob Basha, E.V. Subba Reddy, “ Development and
behaviour of mechanical properties of graphite/granite filled
epoxy hybrid composites”, International journal of fibre and
textile research, ISSN 2277-7156, 2013, pp. 57-59.

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