Unprecedented enhancement of wear resistance for epoxy-resin graphene composites

Penetration resistance of graphene oxide/epoxy resin coating-A molecular dynamics investigation

CONTEXT

The functionalization of graphene is the best way to improve its interfacial compatibility and dispersibility in polymer matrix to obtain high-performance composites. In this study, three nanocomposite models with different salt layer thicknesses were established and simulated by molecular dynamics method to understand the effect of oxygen-containing functional groups on the impermeability of epoxy coatings. Molecular dynamics (MD) simulation results show that the nanocomposites have better impermeability than pure epoxy resin. The thickness of salt solution affects the permeation rate of salt solution and the interfacial properties of nanocomposites. The salt solution molecules trapped in the coating are mainly concentrated at the interface between graphene and epoxy resin, which is the main reason for the decrease in interface properties of epoxy coating.

METHODS

In this paper, Material Studio 8.0 was used to construct nanocomposite models with different salt layer thicknesses (GO/SW7Å, GO/SW10Å, and GO/SW13Å), and MD simulations were performed using a large-scale atomic and molecular parallel simulator (LAMMPS).

Benchmark Study of Epoxy Coatings with Selection of Bio-Based Phenalkamine versus Fossil-Based Amine Crosslinkers

The phenalkamines (PK) derived from cardanol oil can be used as a bio-based crosslinker for epoxy coatings as an alternative for traditional fossil amines (FA). First, the reaction kinetics of an epoxy resin with four PK and FA crosslinkers are compared by differential scanning calorimetry, illustrating a fast reaction rate and higher conversion of PK at room temperature in parallel with a moderate exothermal reaction. Second, the performance of coatings with various concentrations of PK and PK/FA ratios indicates good mixing compatibility between crosslinkers resulting in higher hardness, scratch resistance, hydrophobicity, and abrasive wear resistance of coatings with PK. The superior performance is confirmed over a broad range of resin/crosslinker ratios, facilitating the processing with viscosity profiles depending on the PK type. Although fossil- and bio-based crosslinkers have different chemical structures, the unique linear relationships between intrinsic mechanical properties (i.e., ductility and impact resistance) and coating performance indicate that the degree of crosslinking is a primary parameter controlling coating performance, where PK simultaneously provides high hardness and ductility. In conclusion, the optimization of the processing range for bio-based PK as a crosslinker for epoxy coatings delivers suitable processing conditions and superior mechanical performance compared to traditional amine crosslinkers.

Preparation of Carbon Nanotubes/Alumina Hybrid-Filled Phenolic Composite with Enhanced Wear Resistance

Hybrid fillers can be produced via various methods, such as physical mixing and chemical modification. However, there is a limited number of studies on the effect of hybridisation on the mechanical performance of hybrid filler-reinforced polymer composites, especially in the context of wear performance. This study investigated the wear resistance of carbon nanotubes (CNTs)/alumina hybrid-filled phenolic composite, where two hybrid methods were used to produce the CNTs/alumina hybrid filler. The CNTs/alumina (CVD hybrid) was synthesised using the chemical vapour deposition (CVD) method, whereas the CNTs-/alumina (physically hybrid) was prepared using the ball milling method. The CNTs/alumina hybrid filler was then used as a filler in the phenolic composites. The composites were prepared using a hot mounting press and then subjected to a dry sliding wear test using a pin-on-disc (POD) tester. The results show that the composite filled with the CVD hybrid filler (HYB composite) had better wear resistance than the composite filled with physically hybrid filler (PHY composite) and pure phenolic. At 5 wt%, the HYB composite showed a 74.68% reduction in wear, while the PHY composite showed a 56.44% reduction in wear compared to pure phenolic. The HYB composite exhibited the lowest average coefficient of friction (COF) compared to the PHY composite and pure phenolic. The average COF decreased with increasing sliding speeds and applied loads. The phenolic composites' wear and average COF are in the order HYB composite < PHY composite < pure phenolic under all sliding speeds and applied loads.

A mucus-inspired solvent-free carbon dot-based nanofluid triggers significant tribological synergy for sulfonated h-BN reinforced epoxy composites

Nano-filler reinforced polymer-based composites have attracted extensive attention in tribology; however, to date, it is still challenging to construct a favorable lubricating system with excellent compatibility, lubricity and durability using nano-filler reinforced polymer-based composites. Herein, sulfonated boron nitride nano-sheets (h-BN@PSDA) are prepared and used as nano-fillers for epoxy resins (EPs), to improve friction and wear along with thermal conductivity. Furthermore, inspired by the lubricating principle and structure of snail mucus, a solvent-free carbon dot-based nanofluid (F-CDs) is fabricated and used for the first time as the lubricant for h-BN@PSDA/EPs. Both poly (4-styrene sulfonate) and polyether amine grafted on the surface of F-CDs contribute to branched structures and multiple interfacial absorption effects. Extraordinarily low friction and wear are detected after long-term sliding. The average coefficient of friction and wear rate of h-BN@PSDA/EPs composites are reduced by 95.25% and 99.42% respectively, in the presence of the F-CD nanofluid, compared to that of EPs. Besides, the added h-BN nano-sheets increase the thermal conductivity (TC) of EPs from 0.178 to 0.194 W (m^-1 K^-1). The distinguished lubrication performances are likely due to the formation of a hybrid nanostructure of 0D F-CDs and 2D h-BN@PSDA together with the "rolling-sliding" and "self-mending" effects of added F-CDs.

Influence of Maleinized Polybutadiene on Adhesive Strength and Toughness of Epoxy Resins

This study explored the effect of maleinized polybutadiene (MPB) on the mechanical properties of epoxy resins. Diglycidyl ether of bisphenol-A, an epoxy resin, was modified by incorporating MPB having different molecular weights in order to improve the fracture toughness and peel strength. MPB was mixed with epoxy resin at several concentrations (5, 10, and 15 phr), with the epoxy resin as the major phase and MPB as the minor phase. A comparative study was performed to investigate the influence of MPB on epoxy resins based on their molecular weight difference. Lap shear test results showed that the shear strength of the MPB-modified epoxy resins was superior to that of the neat epoxy resin. At 10 wt% MPB loading, the modified epoxy resin exhibited an 87% enhancement in T-peel strength relative to that of the neat epoxy resin. Moreover, the fracture energy of the modified epoxy system increased proportionally with the amount of MPB in the epoxy matrix. These results indicate that MPB incorporation is a simple and effective method for designing multifunctional epoxy resins, thus facilitating their industrial application in various spheres.

Preparation and Tribological Properties of Bismaleimide Matrix Composites Reinforced with Covalent Organic Framework Coated Graphene Nanosheets

The poor compatibility between the polymer matrix and complex modification processes greatly affects the excellent tribological properties of graphene in the polymer matrix. In this study, a covalent organic framework (COF)-coated graphene hybrid lubricating filler (G/COFs) was synthesized in situ using a sample one-step mechanochemical synthesis process. This was used to improve the tribological properties of bismaleimide (BMI) resin. The morphology and microstructure of the G/COFs hybrid were characterized, and the effect of the added amount on the tribological properties of the G/COFs/BMI composites was studied. The results showed that the G/COFs hybrid could improve the stability of the friction coefficient and decrease the volume wear rate of BMI composites. Compared to the neat BMI, the 0.6 wt% G/COFs/BMI composites showed optimal tribological performance, with the friction coefficient and volume wear rate decreasing from 0.35 to 0.14 and from 48 × 10^-6 to 10.6 × 10^-6 mm³/(N‧m), respectively. In addition, the G/COFs/BMI composites showed lower friction coefficient fluctuations and volume wear rates than G/BMI composites. This is mainly attributed to the fact that the deposition of COFs can not only effectively prevent the aggregation of graphene nanosheets, but can also significantly improve the compatibility and interfacial bond between the graphene and BMI matrix. Moreover, the good synergistic effect between the lamellar COFs and graphene nanosheets can generate high-quality self-lubricating transfer films during the friction process. The excellent dispersibility, efficient chemical functionalization, better friction reduction and wear-resistance properties, and facile preparation method make graphene/COFs hybrid nanoparticles promising as an excellent lubricating filler.

Enhancement of the Water-Lubricated Tribological Properties of Hybrid PTFE/Nomex Fabric Laminate Composite via Epoxy Resin and Graphite Filler

This paper studied a hybrid polytetrafluoroethylene (PTFE)/Nomex fabric composite with lower friction coefficient (COF) and high underwater wear resistance. A pin-on-disk tribometer was used to test tribological properties under different applied loads and rotation speeds. The wear surface, transfer film and cross-section were analyzed by scanning electron microscope (SEM) and optical microscope. The results showed enhanced underwater tribological properties because of excellent self-lubricating properties of PTFE fibers and a good lubricating effect and load-carrying capacity of graphite fillers. Improved underwater mechanical strength was connected to the high strength of epoxy resin and high bonding force between Nomex and epoxy resin.

Tribocatalytically-activated formation of protective friction and wear reducing carbon coatings from alkane environment

Minimizing the wear of the surfaces exposed to mechanical shear stresses is a critical challenge for maximizing the lifespan of rotary mechanical parts. In this study, we have discovered the anti-wear capability of a series of metal nitride-copper nanocomposite coatings tested in a liquid hydrocarbon environment. The results indicate substantial reduction of the wear in comparison to the uncoated steel substrate. Analysis of the wear tracks indicates the formation of carbon-based protective films directly at the sliding interface during the tribological tests. Raman spectroscopy mapping of the wear track suggests the amorphous carbon (a-C) nature of the formed tribofilm. Further analysis of the tribocatalytic activity of the best coating candidate, MoN-Cu, as a function of load (0.25–1 N) and temperature (25 °C and 50 °C) was performed in three alkane solutions, decane, dodecane, and hexadecane. Results indicated that elevated temperature and high contact pressure lead to different tribological characteristics of the coating tested in different environments. The elemental energy dispersive x-ray spectroscopy analysis and Raman analysis revealed formation of the amorphous carbon film that facilitates easy shearing at the contact interface thus enabling more stable friction behavior and lower wear of the tribocatalytic coating. These findings provide new insights into the tribocatalysis mechanism that enables the formation of zero-wear coatings.

Effect of the content of silane-functionalized boron carbide on the mechanical and wear performance of B4C reinforced epoxy composites

This article presents the mechanical, physical, and tribological properties of the boron carbide (B4C) reinforced epoxy matrix composites (BEMCs). The BEMC samples were prepared with various B4C concentration of 0%, 1%, 2%, 3%, and 5%. B4C particles were treated with a silane coupling agent to ensure efficient adhesion with epoxy. The influence of a range of parameters (particle loading, sliding speed, sliding distance, and normal load) on the wear and friction behavior of BEMCs were evaluated by conducting wear tests under dry sliding conditions on a pin-on-disc wear test set-up. The addition of B4C to the epoxy polymer improved the wear resistance of the composites. Maximum wear resistance and coefficient of friction were observed for the composite with the highest percentage of B4C (5%). The specific wear rate was reduced on increasing load and sliding distance and increased with the sliding velocity. Mechanical properties including compression strength, flexural strength, and impact energy, along with physical properties such as density and hardness, were also evaluated. B4C particles improved the hardness, density, flexural and compression strength, and impact resistance of the composites. Scanning electron microscope (SEM) analysis of the worn-out surfaces and flexural fractured surfaces was carried out to predict the possible wear and fracture mechanisms. Micro-ploughing, abrasion, and adhesion were the wear mechanisms in BEMCs. Under the flexural loads, particulate de-bonding, pull-out, and brittle fracture of the matrix were the governing failure mechanisms.

Formation and topological structure of three-dimensional disordered graphene networks

Disordered graphene networks (DGNs) can be regarded as the three-dimensional (3D) assembly of graphene-like fragments at the nanoscale, in which some intrinsic topological features are usually hidden in these formless fragments without clear understanding. Although some high-resolution structural patterns have been observed in pyrolytic carbons and flash graphene experimentally, it is still hard to characterize the topology and texture of DGNs considering continuous 3D connectivity. Toward this end, starting from the annealing process, we herein performed molecular dynamics simulations to investigate the formation and topological structure of DGNs. Three typical stages are found during the formation of DGNs, that is, the formation of polyaromatic fragments, formation of a disordered framework, and further graphitization. The topology of the obtained DGNs was then investigated, including topological defects, stacking behavior, and global curvature. Several typical in-plane and out-of-plane topological defects are found to connect the 3D network of graphene-like layers. The computed X-ray diffraction and angular defects demonstrate that a high-density DGN tends to form a randomly stacked structure with more connections, while a low-density DGN exhibits more bowl-shaped layers and a less distorted curvature. At low annealing temperatures, the local curvature of DGNs is highly distorted, and the structure seems to lack graphitization compared to high-temperature ones.

Melt Processable Novolac Cyanate Ester/Biphenyl Epoxy Copolymer Series with Ultrahigh Glass-Transition Temperature

The rapid progress in silicon carbide (SiC)-based technology for high-power applications expects an increasing operation temperature (up to 250 °C) and awaits reliable packaging materials to unleash their full power. Epoxy-based encapsulant materials failed to provide satisfactory protection under such high temperatures due to the intrinsic weakness of epoxy resins, despite their unmatched good adhesion and processability. Herein, we report a series of copolymers made by melt blending novolac cyanate ester and tetramethylbiphenyl epoxy (NCE/EP) that have demonstrated much superior high-temperature stability over current epoxies. Benefited from the aromatic, rigid backbone and the highly functional nature of the monomers, the highest values achieved for the copolymers are as follows: glass-transition temperature (T_g) above 300 °C, decomposition onset above 400 °C, and char yield above 45% at 800 °C, which are among the highest of the known epoxy chemistry by far. Moreover, the high-temperature aging (250 °C) experiments showed much reduced mass loss of these copolymers compared to the traditional high-temperature epoxy and even the pure NCE in the long term by suppressing hydrolysis degradation mechanisms. The copolymer composition, i.e., NCE to EP ratio, has found to have profound impacts on the resin flowability, thermomechanical properties, moisture absorption, and dielectric properties, which are discussed in this paper with in-depth analysis on their structure-property relationships. The outstanding high-temperature stability, preferred and adjustable processability, and the dielectric properties of the reported NCE/EP copolymers will greatly stimulate further research to formulating robust epoxy molding compounds (EMCs) or underfill for packaging next-generation high-power electronics.