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Jagannath GRR, Basawaraj, Naik Narayana CK, Hulikere Mallaradhya M, Majdi A, Alkahtani MQ, Islam S. Enhancing Wear Resistance of UHMWPE Composites with Micro MoS 2 and Nano Graphite: A Taguchi-DOE Approach. ACS OMEGA 2024; 9:16743-16758. [PMID: 38617631 PMCID: PMC11007771 DOI: 10.1021/acsomega.4c00864] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 01/26/2024] [Revised: 03/03/2024] [Accepted: 03/08/2024] [Indexed: 04/16/2024]
Abstract
This study presents an in-depth investigation into the wear characteristics of ultrahigh-molecular-weight polyethylene (UHMWPE) composites reinforced with microsized MoS2 and nanosized graphite particles. The objective is to enhance the wear resistance of the UHMWPE by examining the effects of various parameters and optimizing the wear performance. To achieve this goal, wet wear tests were conducted under controlled conditions, and the results were compared between composites with micro MoS2 and nano graphite reinforcements. The Taguchi method was employed to design the experiments (DOE) using an L9 orthogonal array. Four key parameters, namely, reinforcement percentage, load, speed, and track radius, were varied systematically to analyze their impact on wear characteristics, including wear rate, frictional forces, and the coefficient of friction (COF). The data obtained from the experiments were subjected to analysis of variance (ANOVA) to identify the significant factors affecting wear behavior. Subsequently, the optimal wear parameters were determined through regression analysis, allowing for the prediction of wear characteristics under the optimum conditions. This research not only provides insights into the comparative performance of micro MoS2 and nano graphite reinforcements in UHMWPE composites but also offers a comprehensive approach to optimizing wear resistance by employing advanced statistical and experimental techniques. The findings contribute to the development of more durable and wear-resistant materials with potential applications in various industries, such as those investigated in the study, which are commonly employed, such as automotive, aerospace, medical devices, or manufacturing.
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Affiliation(s)
- Gadipallya Ranga Rao Jagannath
- Department
of Mechanical Engineering, R.N.S. Institute
of Technology, Affiliated
to Visvesvaraya Technological University, Belagavi, Bengaluru 590018, India
| | - Basawaraj
- Department
of Aerospace Propulsion Technology, VTU-Regional
Centre Muddenahalli, Affiliated to Visvesvaraya Technological University, Belagavi, Bengaluru 560091, India
| | - Channa Keshava Naik Narayana
- Department
of Mechanical Engineering, BGS College of
Engineering and Technology, Affiliated to Visvesvaraya Technological University, Belagavi, Bengaluru 560086, India
| | - Mallaradhya Hulikere Mallaradhya
- Department
of Mechanical Engineering, SJC Institute
of Technology, Affiliated
to Visvesvaraya Technological University, Belagavi, Chickballapura 562101, India
| | - Ali Majdi
- Department
of Buildings and Construction Techniques Engineering, College of Engineering, Al-Mustaqbal University, Hillah 51001, Babylon, Iraq
| | - Meshel Q. Alkahtani
- Civil Engineering
Department, College of Engineering, King
Khalid University, Abha 61421, Saudi Arabia
| | - Saiful Islam
- Civil Engineering
Department, College of Engineering, King
Khalid University, Abha 61421, Saudi Arabia
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Zhong W, Chen S, Tong Z. High-Temperature Tribological Behavior of HDPE Composites Reinforced by Short Carbon Fiber under Water-Lubricated Conditions. MATERIALS 2022; 15:ma15134508. [PMID: 35806633 PMCID: PMC9267907 DOI: 10.3390/ma15134508] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/09/2022] [Revised: 06/11/2022] [Accepted: 06/20/2022] [Indexed: 02/04/2023]
Abstract
The polymer water-lubricated bearing is widely used in marine transmission systems, and the tribological properties can be improved by addition of inorganic nano-fillers. The aim of this study is to investigate the effect of SCFs and temperature on the water-lubricating properties of high-density polyethylene (HDPE) composites. HDPE composites reinforced by varying content of short carbon fibers (SCFs) were fabricated via twin-screw extrusion and injection molding techniques to study the hardness and surface wettability of those composites. The tribological properties under water-lubricated conditions were investigated through a pin-on-disk reciprocating tribometer under different temperatures. The results showed that the increase in hardness of HDPE composites reached maximum to 42.9% after adding 25 wt % SCFs. The contact angle also increased with the increase in SCFs content and reached a maximum of 95.2° as the amount of SCFs increased to 20 wt %. The incorporation of SCFs increased the wear resistance and lubricating property of HDPE composites at different temperatures. The HDPE composite containing 20 wt % SCFs showed the lowest friction coefficient of 0.076 at 40 °C, and the wear track depth reached a maximum of 36.3 mm at 60 °C. Based on the surface wetting property and wear analysis, potential effect mechanisms of fillers and temperature were discussed. The knowledge from this study is useful for designing the anti-wear water-lubricated polymer bearing.
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Affiliation(s)
- Wen Zhong
- The Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu 610039, China;
- Luzhou Laojiao Group Co., Ltd., Luzhou 646000, China
- Correspondence: ; Tel.: +86-159-0282-0426
| | - Siqiang Chen
- The Key Laboratory of Fluid and Power Machinery, Ministry of Education, Xihua University, Chengdu 610039, China;
- Luzhou Laojiao Group Co., Ltd., Luzhou 646000, China
| | - Zhe Tong
- School of Mechanical Engineering, North University of China, Taiyuan 030051, China;
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Xue Y, Yan S, Chen Y. Thermomechanical and tribological properties of polyimide and polyethersulfone blends reinforced with expanded graphite particles at various elevated temperatures. J Appl Polym Sci 2022. [DOI: 10.1002/app.52512] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Ya‐Hong Xue
- Tianjin Key Laboratory for Advanced Mechatronic System Design and Intelligent Control, School of Mechanical Engineering Tianjin University of Technology Tianjin China
- National Demonstration Center for Experimental Mechanical and Electrical Engineering Education Tianjin University of Technology Tianjin China
| | - Shi‐Cheng Yan
- Tianjin Key Laboratory for Advanced Mechatronic System Design and Intelligent Control, School of Mechanical Engineering Tianjin University of Technology Tianjin China
- National Demonstration Center for Experimental Mechanical and Electrical Engineering Education Tianjin University of Technology Tianjin China
| | - Yuan Chen
- Tianjin Key Laboratory for Advanced Mechatronic System Design and Intelligent Control, School of Mechanical Engineering Tianjin University of Technology Tianjin China
- National Demonstration Center for Experimental Mechanical and Electrical Engineering Education Tianjin University of Technology Tianjin China
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Effect of Borpolymer on Mechanical and Structural Parameters of Ultra-High Molecular Weight Polyethylene. NANOMATERIALS 2021; 11:nano11123398. [PMID: 34947747 PMCID: PMC8703745 DOI: 10.3390/nano11123398] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 11/02/2021] [Revised: 12/07/2021] [Accepted: 12/13/2021] [Indexed: 11/30/2022]
Abstract
The paper presents the results of studying the effect of borpolymer (BP) on the mechanical properties, structure, and thermodynamic parameters of ultra-high molecular weight polyethylene (UHMWPE). Changes in the mechanical characteristics of polymer composites material (PCM) are confirmed and complemented by structural studies. X-ray crystallography (XRC), differential scanning calorimetry (DSC), scanning electron microscopy (SEM), and infrared spectroscopy (IR) were used to study the melting point, morphology and composition of the filler, which corresponds to the composition and data of the certificate of the synthesized BP. Tensile and compressive mechanical tests were carried out in accordance with generally accepted standards (ASTM). It is shown that BP is an effective modifier for UHMWPE, contributing to a significant increase in the deformation and strength characteristics of the composite: tensile strength of PCM by 56%, elongation at break by 28% and compressive strength at 10% strain by 65% compared to the initial UHMWPE, due to intensive changes in the supramolecular structure of the matrix. Structural studies revealed that BP does not chemically interact with UHMWPE, but due to its high adhesion to the polymer, it acts as a reinforcing filler. SEM was used to establish the formation of a spherulite supramolecular structure of polymer composites.
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Rothammer B, Neusser K, Marian M, Bartz M, Krauß S, Böhm T, Thiele S, Merle B, Detsch R, Wartzack S. Amorphous Carbon Coatings for Total Knee Replacements-Part I: Deposition, Cytocompatibility, Chemical and Mechanical Properties. Polymers (Basel) 2021; 13:1952. [PMID: 34208302 PMCID: PMC8231215 DOI: 10.3390/polym13121952] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/19/2021] [Revised: 06/09/2021] [Accepted: 06/09/2021] [Indexed: 11/17/2022] Open
Abstract
Diamond-like carbon (DLC) coatings have the potential to reduce implant wear and thus to contribute to avoiding premature failure and increase service life of total knee replacements (TKAs). This two-part study addresses the development of such coatings for ultrahigh molecular weight polyethylene (UHMWPE) tibial inlays as well as cobalt-chromium-molybdenum (CoCr) and titanium (Ti64) alloy femoral components. While a detailed characterization of the tribological behavior is the subject of part II, part I focusses on the deposition of pure (a-C:H) and tungsten-doped hydrogen-containing amorphous carbon coatings (a-C:H:W) and the detailed characterization of their chemical, cytological, mechanical and adhesion behavior. The coatings are fabricated by physical vapor deposition (PVD) and display typical DLC morphology and composition, as verified by focused ion beam scanning electron microscopy and Raman spectroscopy. Their roughness is higher than that of the plain substrates. Initial screening with contact angle and surface tension as well as in vitro testing by indirect and direct application indicate favorable cytocompatibility. The DLC coatings feature excellent mechanical properties with a substantial enhancement of indentation hardness and elastic modulus ratios. The adhesion of the coatings as determined in modified scratch tests can be considered as sufficient for the use in TKAs.
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Affiliation(s)
- Benedict Rothammer
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.M.); (M.B.); (S.W.)
| | - Kevin Neusser
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.M.); (M.B.); (S.W.)
| | - Max Marian
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.M.); (M.B.); (S.W.)
| | - Marcel Bartz
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.M.); (M.B.); (S.W.)
| | - Sebastian Krauß
- Materials Science & Engineering, Institute I, Interdisciplinary Center for Nanostructured Films (IZNF), Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Cauerstr. 3, 91058 Erlangen, Germany; (S.K.); (B.M.)
| | - Thomas Böhm
- Forschungszentrum Jülich GmbH, Helmholtz-Institute Erlangen-Nürnberg for Renewable Energy, Cauerstr. 1, 91058 Erlangen, Germany; (T.B.); (S.T.)
| | - Simon Thiele
- Forschungszentrum Jülich GmbH, Helmholtz-Institute Erlangen-Nürnberg for Renewable Energy, Cauerstr. 1, 91058 Erlangen, Germany; (T.B.); (S.T.)
- Department of Chemical and Biological Engineering, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Egerlandstr. 3, 91058 Erlangen, Germany
| | - Benoit Merle
- Materials Science & Engineering, Institute I, Interdisciplinary Center for Nanostructured Films (IZNF), Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Cauerstr. 3, 91058 Erlangen, Germany; (S.K.); (B.M.)
| | - Rainer Detsch
- Department of Materials Science and Engineering, Institute of Biomaterials, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Cauerstr. 6, 91058 Erlangen, Germany;
| | - Sandro Wartzack
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.M.); (M.B.); (S.W.)
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Rothammer B, Marian M, Neusser K, Bartz M, Böhm T, Krauß S, Schroeder S, Uhler M, Thiele S, Merle B, Kretzer JP, Wartzack S. Amorphous Carbon Coatings for Total Knee Replacements-Part II: Tribological Behavior. Polymers (Basel) 2021; 13:1880. [PMID: 34198895 PMCID: PMC8201056 DOI: 10.3390/polym13111880] [Citation(s) in RCA: 8] [Impact Index Per Article: 2.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/19/2021] [Revised: 06/02/2021] [Accepted: 06/02/2021] [Indexed: 12/27/2022] Open
Abstract
Diamond-like carbon coatings may decrease implant wear, therefore, they are helping to reduce aseptic loosening and increase service life of total knee arthroplasties (TKAs). This two-part study addresses the development of such coatings for ultrahigh molecular weight polyethylene (UHMWPE) tibial inlays as well as cobalt-chromium-molybdenum (CoCr) and titanium (Ti64) alloy femoral components. While the deposition of a pure (a-C:H) and tungsten-doped hydrogen-containing amorphous carbon coating (a-C:H:W) as well as the detailed characterization of mechanical and adhesion properties were the subject of Part I, the tribological behavior is studied in Part II. Pin-on-disk tests are performed under artificial synovial fluid lubrication. Numerical elastohydrodynamic lubrication modeling is used to show the representability of contact conditions for TKAs and to assess the influence of coatings on lubrication conditions. The wear behavior is characterized by means of light and laser scanning microscopy, Raman spectroscopy, scanning electron microscopy and particle analyses. Although the coating leads to an increase in friction due to the considerably higher roughness, especially the UHMWPE wear is significantly reduced up to a factor of 49% (CoCr) and 77% (Ti64). Thereby, the coating shows continuous wear and no sudden failure or spallation of larger wear particles. This demonstrated the great potential of amorphous carbon coatings for knee replacements.
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Affiliation(s)
- Benedict Rothammer
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.B.); (S.W.)
| | - Max Marian
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.B.); (S.W.)
| | - Kevin Neusser
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.B.); (S.W.)
| | - Marcel Bartz
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.B.); (S.W.)
| | - Thomas Böhm
- Forschungszentrum Jülich GmbH, Helmholtz-Institute Erlangen-Nürnberg for Renewable Energy, Cauerstr. 1, 91058 Erlangen, Germany; (T.B.); (S.T.)
| | - Sebastian Krauß
- Department of Materials Science & Engineering, Interdisciplinary Center for Nanostructured Films (IZNF) Institute I, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Cauerstr. 3, 91058 Erlangen, Germany; (S.K.); (B.M.)
| | - Stefan Schroeder
- Laboratory of Biomechanics and Implant Research, Clinic for Orthopedics and Trauma Surgery, Heidelberg University Hospital, Schlierbacher Landstr. 200a, 69118 Heidelberg, Germany; (S.S.); (M.U.); (J.P.K.)
| | - Maximilian Uhler
- Laboratory of Biomechanics and Implant Research, Clinic for Orthopedics and Trauma Surgery, Heidelberg University Hospital, Schlierbacher Landstr. 200a, 69118 Heidelberg, Germany; (S.S.); (M.U.); (J.P.K.)
| | - Simon Thiele
- Forschungszentrum Jülich GmbH, Helmholtz-Institute Erlangen-Nürnberg for Renewable Energy, Cauerstr. 1, 91058 Erlangen, Germany; (T.B.); (S.T.)
- Department of Chemical and Biological Engineering, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Egerlandstr. 3, 91058 Erlangen, Germany
| | - Benoit Merle
- Department of Materials Science & Engineering, Interdisciplinary Center for Nanostructured Films (IZNF) Institute I, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Cauerstr. 3, 91058 Erlangen, Germany; (S.K.); (B.M.)
| | - Jan Philippe Kretzer
- Laboratory of Biomechanics and Implant Research, Clinic for Orthopedics and Trauma Surgery, Heidelberg University Hospital, Schlierbacher Landstr. 200a, 69118 Heidelberg, Germany; (S.S.); (M.U.); (J.P.K.)
| | - Sandro Wartzack
- Engineering Design, Friedrich-Alexander-University Erlangen-Nuremberg (FAU), Martensstr. 9, 91058 Erlangen, Germany; (K.N.); (M.B.); (S.W.)
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Panin SV, Buslovich DG, Dontsov YV, Bochkareva SA, Kornienko LA, Berto F. UHMWPE-Based Glass-Fiber Composites Fabricated by FDM. Multiscaling Aspects of Design, Manufacturing and Performance. MATERIALS 2021; 14:ma14061515. [PMID: 33808909 PMCID: PMC8003805 DOI: 10.3390/ma14061515] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/20/2021] [Revised: 03/12/2021] [Accepted: 03/16/2021] [Indexed: 11/16/2022]
Abstract
The aim of the paper was to improve the functional properties of composites based on ultra-high molecular weight polyethylene (UHMWPE) by loading with reinforcing fibers. It was achieved by designing the optimal composition for its subsequent use as a feedstock for 3D-printing of guides for roller and plate chains, conveyors, etc. As a result, it was experimentally determined that loading UHMWPE with 17% high density polyethylene grafted with VinylTriMethoxySilane (HDPE-g-VTMS) was able to bind 5% glass fillers of different aspect ratios, thereby determining the optimal mechanical and tribological properties of the composites. Further increasing the content of the glass fillers caused a deterioration in their tribological properties due to insufficient adhesion of the extrudable matrix due to the excessive filler loading. A multi-level approach was implemented to design the high-strength anti-friction ‘UHMWPE+17%HDPE-g-VTMS+12%PP’-based composites using computer-aided algorithms. This resulted in the determination of the main parameters that provided their predefined mechanical and tribological properties and enabled the assessment of the possible load-speed conditions for their operation in friction units. The uniform distribution of the fillers in the matrix, the pattern of the formed supermolecular structure and, as a consequence, the mechanical and tribological properties of the composites were achieved by optimizing the values of the main control parameters (the number of processing passes in the extruder and the aspect ratio of the glass fillers).
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Affiliation(s)
- Sergey V. Panin
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science SB RAS, 634055 Tomsk, Russia; (D.G.B.); (Y.V.D.); (S.A.B.); (L.A.K.)
- Department of Materials Science, Engineering School of Advanced Manufacturing Technologies, National Research Tomsk Polytechnic University, 634030 Tomsk, Russia
- Correspondence: ; Tel.: +7-3822-286-904
| | - Dmitry G. Buslovich
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science SB RAS, 634055 Tomsk, Russia; (D.G.B.); (Y.V.D.); (S.A.B.); (L.A.K.)
- Department of Materials Science, Engineering School of Advanced Manufacturing Technologies, National Research Tomsk Polytechnic University, 634030 Tomsk, Russia
| | - Yuri V. Dontsov
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science SB RAS, 634055 Tomsk, Russia; (D.G.B.); (Y.V.D.); (S.A.B.); (L.A.K.)
- Department of Materials Science, Engineering School of Advanced Manufacturing Technologies, National Research Tomsk Polytechnic University, 634030 Tomsk, Russia
| | - Svetlana A. Bochkareva
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science SB RAS, 634055 Tomsk, Russia; (D.G.B.); (Y.V.D.); (S.A.B.); (L.A.K.)
| | - Lyudmila A. Kornienko
- Laboratory of Mechanics of Polymer Composite Materials, Institute of Strength Physics and Materials Science SB RAS, 634055 Tomsk, Russia; (D.G.B.); (Y.V.D.); (S.A.B.); (L.A.K.)
| | - Filippo Berto
- Department of Mechanical and Industrial Engineering, Faculty of Engineering, Norwegian University of Science and Technology (NTNU), 7491 Trondheim, Norway;
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