J. R. Gomes

Tribological behaviour of Si3N4–BN ceramic materials for dry sliding applications

The main objective of this paper is to help on the clarification of the lack of consensus in the bibliographic data concerning the tribological behaviour of Si3N4–BN composites. Unlubricated sliding tests by pin-on-disc were carried out with three grades of composite materials with 10, 18 and 25 vol.% of BN. The addition of BN to the Si3N4 matrix resulted in a slight reduction of the friction coefficient, which decreased from 0.82 for monolithic Si3N4 to 0.67 for Si3N4–10%BN materials. Wear coefficients ( K) were above 10 −5 mm 3 N −1 m −1 for all materials tested and increased sharply with increases in BN volume fraction greater than 10%, e.g. K ∼ 10 −3 mm 3 N −1 m −1 for Si3N4–25%BN. The lowest values of friction and wear coefficients were obtained when the composites were tested with the BN platelets oriented parallel to the sliding direction. The morphological study of the worn surfaces revealed generalised brittle intergranular microcracking at the dispersoid/matrix interface as the main wear mechanism. Under the experimental conditions of this study, the formation of stable protective layers of the soft lubricious oxide H 3BO3, or the solid lubricant BN·H2O, was not observed.

The effect of sliding speed and temperature on the tribological behaviour of carbon–carbon composites

Abstract Although the current use of carbon fibre reinforced composites (CFRC) as light weight mechanical resistant components in automotive and aircraft industries, namely in tribological systems such as high energy brake applications, there are few studies concerning the tribological behaviour of these materials in other sliding conditions. Sliding experiments were performed in a pin-on-disc tribometer in air, applying 100xa0N load, in the temperature range of 22–600°C, for three different sliding speeds (0.5, 2.0 and 3.5xa0mxa0s −1 ). Unidirectional CFRC composite (PAN/resin carbon) pins and 2D-CFRC (rayon/resin carbon) composite discs were tested. The morphological features of the sliding surfaces were analysed by scanning electron and optical microscopies in order to understand the friction and wear mechanisms of carbon–carbon materials. At room temperature and low sliding speed (0.5xa0mxa0s −1 ) the wear coefficient was extremely low ( K −6 xa0mm 3 xa0N −1 xa0m −1 ). However, the wear values increased in three orders of magnitude for a sliding speed of 3.5xa0mxa0s −1 . The same trend was observed when comparing results taken at 22 and 300°C or above. At room temperature, the friction coefficient was almost independent of the sliding speed, with values around 0.25, while a decrease to near 0.10 was obtained from tests at higher temperatures. The main conclusion of this work is that carbon–carbon composites show unique properties as wear resistant materials at room temperature and moderate sliding speeds under unlubricated conditions. However, direct or frictional heating may deteriorate the tribological response of such materials due to fibre debonding and fracture.

Tribocorrosion behavior of veneering biomedical PEEK to Ti6Al4V structures.

In dentistry, prosthetic structures must be able to support masticatory loads combined with a high biocompatibility and wear resistance in the presence of a corrosive environment. In order to improve the simultaneous wear and corrosion response of highly biocompatible prosthetic structures, a veneering poly-ether-ether-ketone (PEEK) to Ti6Al4V substrate was assessed by tribocorrosion analyses under conditions mimicking the oral environment. Samples were synthesized by hot pressing the PEEK veneer onto Ti6Al4V cylinders. The tribocorrosion tests on Ti6Al4V or PEEK/Ti6Al4V samples were performed on a reciprocating ball-on-plate tribometer at 30N normal load, 1Hz and stroke length of 3mm. The tests were carried out in artificial saliva at 37°C. Open circuit potential (OCP) was measured before, during and after reciprocating sliding tests. The worn surfaces were characterized by scanning electron microscopy. The results revealed a lower wear rate on PEEK combined with a lower coefficient of friction (COF), when compared to Ti6Al4V. In fact, PEEK protected Ti6Al4V substrate against the corrosive environment and wear avoiding the release of metallic ions to the surrounding environment.

Sliding speed-temperature wear transition maps for Si3N4/iron alloy couples

Abstract The superior high temperature resistance of silicon nitride (Si 3 N 4 ) based ceramics makes them suitable for tribological applications above room temperature or in high speed unlubricated sliding. There are some published works on the wear behaviour of Si 3 N 4 /metal alloys. However, experimental data are shown in a form that is not of direct use for engineers involved in materials selection. In the present work, Si 3 N 4 pins were tested against tool steel and grey cast iron on a pin-on-disc tribometer. Ceramics were produced by hot-pressing and tested without lubrication at variable temperature and sliding speed. SEM/EDS and XRD analysis were used for chemical and microstructural characterisation of worn surfaces and wear debris. At low speeds (0.05–0.5xa0mxa0s −1 ) and room temperature, Si 3 N 4 surfaces are polished-like due to a combination of humidity-assisted tribo-oxidation and abrasive action of very fine wear debris. At high sliding speeds (2–3.5xa0mxa0s −1 ), as well as for temperatures in the range 400–600°C, an extensive coherent tribolayer mainly composed by iron oxides spreads over the ceramic surfaces. Polishing and protection by adherent tribolayers are the mechanisms responsible for observed severe and mild wear regimes, respectively. Wear maps are constructed showing the transition of wear regimes in Si 3 N 4 /iron alloys contacts determined by constant flash temperature curves. Equations for calculation of bulk and flash contact temperatures in tribocontacts between dissimilar materials are deduced.

Comparison between PEEK and Ti6Al4V concerning micro-scale abrasion wear on dental applications.

In the oral cavity, abrasive wear is predictable at exposed tooth or restorative surfaces, during mastication and tooth brushing. Also, wear can occur at contacting surfaces between the Ti-based prosthetic structures and implants in presence of abrasive compounds from food or toothpaste. Thus, the aim of this work was to compare the abrasive wear resistance of PEEK and Ti6Al4V on three-body abrasion related to different hydrated silica content and loads. Surfaces of Ti6Al4V or PEEK cylinders (8mm diameter and 4mm height) were wet ground on SiC papers and then polished with 1µm diamond paste. After that, surfaces were ultrasonically cleaned in propyl alcohol for 15min and then in distilled water for 10min. Micro-scale abrasion tests were performed at 60rpm and on different normal loads (0.4, 0.8 or 1.2N) after 600 ball revolutions using suspensions with different weight contents of hydrated silica. After abrasive tests, wear scars on flat samples were measured to quantify the wear volume and characterized by scanning electron microscope (SEM) to identify the dominant wear mechanisms. Results showed a higher volume loss rate on PEEK than that recorded on Ti6Al4V,, when subjected to three-body abrasion tests involving hydrated silica suspensions. An increase in volume loss was noted on both tested materials when the abrasive content or load was increased. PEEK was characterized by less wear resistance than that on Ti6Al4V after micro-scale abrasion wear in contact with hydrated silica particles, as commonly found in toothpastes.

Tribological behavior of Ti6Al4V cellular structures produced by Selective Laser Melting

Additive manufacturing (AM) technologies enable the fabrication of innovative structures with complex geometries not easily manufactured by traditional processes. Regarding metallic cellular structures with tailored/customized mechanical and wear performance aiming to biomedical applications, Selective Laser Melting (SLM) is a remarkable solution for their production. Focusing on prosthesis and implants, in addition to a suitable Youngs modulus it is important to assess the friction response and wear resistance of these cellular structures in a natural environment. In this sense, five cellular Ti6Al4V structures with different open-cell sizes (100-500µm) were designed and produced by SLM. These structures were tribologicaly tested against alumina using a reciprocating sliding ball-on-plate tribometer. Samples were submerged in Phosphate Buffered Saline (PBS) fluid at 37°C, in order to mimic in some extent the human body environment. The results showed that friction and wear performance of Ti6Al4V cellular structures is influenced by the structure open-cell size. The higher wear resistance was obtained for structures with 100µm designed open-cell size due to the higher apparent area of contact to support tribological loading.

Improvement on Sliding Wear Behavior of Al/Cast Iron Tribopair by CNT's Reinforcement of an Al Alloy

The results presented in this work show the wear characterization of Al-Si matrix composites reinforced by multiwall carbon nanotubes (MWCNTs) under dry reciprocating sliding conditions against a grey cast iron (GCI) The wear resistance is investigated as a function of the carbon nanotube (CNT) content that varied from 2 to 6 wt%. The results demonstrated that the CNT content plays a relevant role in the wear behavior by substantially reducing the wear loss of Al-Si CNT composites. Further, it reduces the wear loss of the grey cast iron counterface. A physical model able to explain the improved behavior in both mating materials is depicted from experimental results.

Laser surface structuring of Ti6Al4V substrates for adhesion enhancement in Ti6Al4V-PEEK joints

PEEK is a promising polymer possessing high mechanical strength and biocompatibility and therefore it can be associated to titanium for biomedical applications. This study aimed at producing Ti6Al4V-PEEK joints with enhanced adhesion through laser-structuring Ti6Al4V treatments. Ti6Al4V cylindrical substrates were prepared by two types of surface treatments: alumina blasting and laser structuring. The holes number and size in laser-structured surfaces was varied. PEEK was then hot pressed against the metallic substrate to completely filling the surface cavities. The adhesion of the PEEK/Ti6Al4V joint was assessed by a shear bond strength test. Fracture surfaces and interfaces were investigated by SEM/EDS. Significant differences were found in the shear bond strength between alumina blasted and laser-structured samples. Bond strength improvement (exceeding 300%) was registered for the laser-structured specimens relative to grit-blasted ones. The laser-structuring technique showed to be very promising in the production of specifically designed surfaces for high strength and mechanically stable Ti6Al4V/PEEK joints.

Bioactive materials driven primary stability on titanium biocomposites

The Ti6Al4V alloy constitutes an alternative choice to the most common metal-polymer solutions for total hip arthroplasty (THA) due to good biocompatibility, optimal mechanical properties and high load bearing capacity. However, as Ti6Al4V is not bioactive in its conventional form, hydroxyapatite (HAp) and tricalcium phosphate (TCP) have been widely used as coatings of metal prostheses due to their osteogenic properties and ability to form strong bonds with bone tissue. A promising approach consists in creating a bioactive surface metal matrix composite Ti6Al4V+β-TCP or Ti6Al4V+HAp, obtained by hot pressing (HP) of powders. In this work, the tribological performance of Ti6Al4V+β-TCP and Ti6Al4V+HAp composites is studied to evaluate the frictional response and surface damage representative of prosthesis implantation, key factors in bone fixation. Biocomposites with 10vol% β-TCP and 10vol% Hap, as well as base titanium alloy, were prepared by HP with two surface finishing conditions - polished (Ra=0.3-0.5μm) and sandblasted (Ra=2.1-2.5μm) - for tribological testing against bovine cortical bone tissue. The static friction increases with surface roughness (from 0.20 to 0.60), whereas the kinetic regime follows an inverse trend for the biocomposites. In contrast with current knowledge, this study shows that an implant design solution based on Ti6Al4V+β-TCP or Ti6Al4V+HAp biocomposites with polished surfaces results in an improved primary stability of implants, when compared to traditional rough surfaces. Moreover, it is also expected that the secondary stability will improve due to the adhesion between bone and HAp/β-TCP, increasing the overall stability of the implant.

Electrically Conductive Polyetheretherketone Nanocomposite Filaments: From Production to Fused Deposition Modeling

The present work reports the production and characterization of polyetheretherketone (PEEK) nanocomposite filaments incorporating carbon nanotubes (CNT) and graphite nanoplates (GnP), electrically conductive and suitable for fused deposition modeling (FDM) processing. The nanocomposites were manufactured by melt mixing and those presenting electrical conductivity near 10 S/m were selected for the production of filaments for FDM. The extruded filaments were characterized for mechanical and thermal conductivity, polymer crystallinity, thermal relaxation, nanoparticle dispersion, thermoelectric effect, and coefficient of friction. They presented electrical conductivity in the range of 1.5 to 13.1 S/m, as well as good mechanical performance and higher thermal conductivity compared to PEEK. The addition of GnP improved the composites’ melt processability, maintained the electrical conductivity at target level, and reduced the coefficient of friction by up to 60%. Finally, three-dimensional (3D) printed test specimens were produced, showing a Young’s modulus and ultimate tensile strength comparable to those of the filaments, but a lower strain at break and electrical conductivity. This was attributed to the presence of large voids in the part, revealing the need for 3D printing parameter optimization. Finally, filament production was up-scaled to kilogram scale maintaining the properties of the research-scale filaments.