scholarly journals Recent Advances in UHMWPE/UHMWPE Nanocomposite/UHMWPE Hybrid Nanocomposite Polymer Coatings for Tribological Applications: A Comprehensive Review

Polymers ◽  
2021 ◽  
Vol 13 (4) ◽  
pp. 608 ◽  
Author(s):  
Mohammed Abdul Samad
Keyword(s):  
Low Cost ◽  
Composite Coatings ◽  
Composite Films ◽  
Polymer Coatings ◽  
High Wear Resistance ◽  
Low Friction ◽  
Corrosion Properties ◽  
Polyether Ether Ketone ◽  
Nanocomposite Polymer ◽  
Wear And Corrosion

In the recent past, polymer coatings have gained the attention of many researchers due to their low cost, their ability to be coated easily on different substrates, low friction and good anti-corrosion properties. Various polymers such as polytetrafluroethylene (PTFE), polyether ether ketone (PEEK), polymethylmethacrylate (PMMA), polyurethane (PU), polyamide (PA), epoxy and ultra-high molecular weight polytheylene (UHMWPE) have been used to develop these coatings to modify the surfaces of different components to protect them from wear and corrosion. However, among all these polymers, UHMWPE stands out as a tribologist’s polymer due to its low friction and high wear resistance. These coatings have found their way into applications ranging from microelectro mechanical systems (MEMS) to demanding tribological applications such as bearings and biomedical applications. Despite its excellent tribological properties, UHMWPE suffers from limitations such as low load bearing capacity and low thermal stability. To overcome these challenges researchers have developed various routes such as developing UHMWPE composite and hybrid composite coatings with several types of nano/micro fillers, developing composite films system and developing dual film systems. The present paper is an effort to summarize these various routes adopted by different researchers to improve the tribological performance of UHMWPE coatings.

Low friction bio-inspired polydopamine/polytetrafluoroethylene coating performance in hydrodynamic bearings

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Marius Rutkevičius ◽  
Jimmy Dong ◽  
Darren Tremelling ◽  
Julia Viertel ◽  
Samuel Beckford
Keyword(s):  
Large Scale ◽  
Journal Bearing ◽  
Low Cost ◽  
Optical Microscope ◽  
Polymer Coatings ◽  
Industrial Applications ◽  
Low Friction ◽  
Coating Performance ◽  
Content Type ◽  
Coating Delamination

Purpose Low friction polymer coatings able to withstand high loadings and many years of continuous operation are difficult to formulate at low cost, but could find many applications in industry. This study aims to analyze and compare friction and wear performance of novel polydopamine/polytetrafluoroethylene (PDA/PTFE) and traditional tin Babbitt coatings applied to an industrial journal bearing. Design/methodology/approach This paper tested PTFE based coating, co-deposited with PDA, a biopolymer allowing sea mussels to adhere to ocean rocks. This coating was deposited on flat steel substrates and on a curved cast iron hydrodynamic journal bearing surface. The flat substrates were analyzed with a tribometer and an optical microscope, while the coated bearing liners were tested in an industrial laboratory setting at different speeds and different radial loads. Findings PDA/PTFE coating showed 2-3 times lower friction compared to traditional tin Babbitt for flat substrates, but higher friction in the bearing liners. PDA/PTFE also showed considerable wear through coating delamination and abrasion in the bearing liners. Research limitations/implications Five future modifications to mitigate coating flaws are provided, which include modifications to coating thickness and its surface finish. Originality/value While the novel coating showed excellent results on flat substrates, coating performance in a large scale bearing was found to be poor. This study shows that coating preparation needs to be improved to avoid frictional losses and unwanted damage to bearings. We provide several routes that could improve coating performance in industrial applications.

Carbon Based Coatings for Hermetic Compressor Applications

2014 ◽  
Vol 89 ◽  
pp. 21-30
Author(s):  
Jose Daniel Biasoli de Mello
Keyword(s):  
Surface Engineering ◽  
Low Cost ◽  
Constant Load ◽  
High Wear Resistance ◽  
Tribological Behaviour ◽  
Low Friction ◽  
Dlc Coating ◽  
The Usa ◽  
Hermetic Compressor

Household refrigeration represents 17.3% of home energy consumption in the USA and 47% in Brazil. This article overviews a multidisciplinary approach to develop a traditional hermetic compressor (oil lubricated, with several rotating parts), into an oil-less, linear motion, innovative compressor, with improved efficiency, versatility and sustainability. This involves the development of surface engineering processes combining purpose-oriented phases applied to soft substrates to achieve high wear resistance and load support and low friction coefficient. Initially, the role of the environment (air, CO2 and R600a) on the tribological behaviour of a commercially available Si-rich multifunctional DLC coating deposited on AISI 1020 steel is illustrated. In sequence, the influence of the thickness of different layers (DLC and CrN) on sliding wear is analysed. Results are presented using an original approach (3D triboscopic maps) for two distinct configurations (increasing load and constant load) and findings are confronted with numerical simulations using Film Doctor®. Finally, a low cost process to obtain a multifunctional coating (different nitrided layers + DLC) is described, which uses a unique thermal cycle reactor capable of coating parts in industrial scale with reduced cost.

scholarly journals A review on tribology of polymer composite coatings

Friction ◽  
2020 ◽  
Author(s):  
Yilong Ren ◽  
Lin Zhang ◽  
Guoxin Xie ◽  
Zhanbo Li ◽  
Hao Chen ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Composite Coating ◽  
Polymer Composite ◽  
Composite Coatings ◽  
Polymer Coatings ◽  
Operating Conditions ◽  
High Wear Resistance ◽  
Design Strategies ◽  
Adhesion Properties ◽  
Functional Fillers

AbstractSelf-lubricating polymer composite coatings, with tailorable tribological and mechanical properties, have been widely employed on mechanical parts to reduce friction and wear, which saves energy and improves the overall performance for applications such as aerospace satellite parts, shafts, gears, and bushings. The addition of functional fillers can overcome the limitations of single-polymer coatings and extend the service life of the coatings by providing a combination of low friction, high wear resistance, high load bearing, high temperature resistance, and high adhesion. This paper compares the heat resistance, and the tribological and mechanical properties of common polymer matrices, as well as the categories of functional fillers that improve the coating performance. Applicable scopes, process parameters, advantages, and limitations of the preparation methods of polymer coatings are discussed in detail. The tribological properties of the composite coatings with different matrices and fillers are compared, and the lubrication mechanisms are analyzed. Fillers reduce friction by promoting the formation of transfer films or liquid shear films. Improvement of the mechanical properties of the composite coatings with fillers of different morphologies is described in terms of strengthening and toughening mechanisms, including a stress transfer mechanism, shear yielding, crack bridging, and interfacial debonding. The test and enhancement methods for the adhesion properties between the coating and substrate are discussed. The coating adhesion can be enhanced through mechanical treatment, chemical treatment, and energy treatment of the substrate. Finally, we propose the design strategies for high-performance polymer composite coating systems adapted to specific operating conditions, and the limitations of current polymer composite coating research are identified.

Fabrication and Characterization of Hydroxyapatite-Magnesium Composite Thin Films on Magnesium Plates for Implant Applications

2012 ◽  
Author(s):  
Kwadwo Mensah-Darkwa ◽  
Ram K. Gupta ◽  
Dhananjay Kumar
Keyword(s):  
Thin Films ◽  
Potentiodynamic Polarization ◽  
Composite Coatings ◽  
Composite Films ◽  
Corrosion Current ◽  
Biological Properties ◽  
Cytotoxicity Test ◽  
Corrosion Properties ◽  
Composite Thin Films ◽  
X Ray

Hydroxyapatite (HA)-magnesium (Mg) composite thin films were grown on magnesium substrates using a multitarget pulsed laser deposition technique. The microstructural and corrosion properties of HA-Mg composite thin films were investigated using methods such as x-ray diffraction (XRD), scanning electron microscopy (SEM), energy dispersive x-ray (EDX) analysis, and potentiodynamic polarization. While the XRD studies have indicated the amorphous nature of the HA-Mg composite coating, SEM and EDX studies have shown that the composite films are stoichiometric. The potentiodynamic polarization study indicates that the corrosion of magnesium decreases with increase in the hydroxyapatite content in the composite film. The corrosion potential (Ecorr) and corrosion current density (Icorr) for the uncoated magnesium, 30HA-70Mg, and 50HA-50Mg coated magnesium are −1.59, −1.57, −1.54 V and 1.21×10−5, 1.38×10−6, 2.52×10−7 A/cm2, respectively. Preliminary cytotoxicity test conducted on the samples shows no adverse effect on human bone marrow stromal cells. The advantage of the composite coatings is the realization of adjustable corrosion and biological properties by a simple maneuvering of composition which in turn is realized by changing the number of laser pulses on a respective target.

Wear and Corrosion Resistance of High-Velocity Oxygen-Fuel Sprayed Iron-Based Composite Coatings

2013 ◽  
Author(s):  
A. Milanti ◽  
H. Koivuluoto ◽  
P. Vuoristo ◽  
G. Bolelli ◽  
F. Bozza ◽  
...  
Keyword(s):  
Wear Resistance ◽  
Corrosion Resistance ◽  
High Velocity ◽  
Composite Coatings ◽  
Electrochemical Behaviour ◽  
Microstructural Characterization ◽  
Wear Properties ◽  
Corrosion Properties ◽  
Wear And Corrosion ◽  
Iron Based

Thermally sprayed iron-based coatings are being widely studied as alternative solution to conventional hardmetal (cermet) and Ni-based coatings for wear and corrosion applications in order to reduce costs, limit environmental impact and enhance the health safety. The aim of the present work is to study the cavitation erosion behaviour in distilled water and the corrosion properties in acidic solution of four high-velocity oxy-fuel (HVOF) sprayed Fe-based composite coatings. Fe-Cr-Ni-B-C powder was selected for its good sliding wear properties. In addition, a powder composition with an addition of Mo was studied in order to increase the corrosion resistance whereas additions of 20 wt. % and 40 wt. % WC-12Co as blended powder mixtures were investigated in order to increase wear resistance. Improvement of coating properties was significant with the advanced powder compositions. Dense coating structures with low porosity were detected with microstructural characterization. In addition, good cavitation wear resistance was achieved. The cavitation resistance of customized Fe-based coating with Mo addition was reported to be twice as high as that of conventional Ni-based and WC-CoCr coatings. The corrosion properties of HVOF Fe-based coatings were also evaluated by studying electrochemical behaviour in order to analyse their potential to use as corrosion barrier coatings.

Electrophoretic Deposition of Ni/SiO2 Nanocomposite Coating: Fabrication Process and Tribological and Corrosion Properties

2013 ◽  
Vol 26 ◽  
pp. 45-51 ◽  
Author(s):  
Arash Ghalayani Isfahani ◽  
Mohammad Ghorbani
Keyword(s):  
Electrophoretic Deposition ◽  
Proper Time ◽  
Contact Stiffness ◽  
Composite Coatings ◽  
Nanocomposite Coating ◽  
Nanocomposite Coatings ◽  
Optimum Conditions ◽  
Time Duration ◽  
Corrosion Properties ◽  
Wear And Corrosion

To the best of our knowledge, this work presents the first successful effort to fabricate and study nanostructured Ni-based composite coatings using the electrophoretic deposition method with nanostructured SiO2particles. In this work, Ni/SiO2nanoparticle composite coatings were prepared by electrophoretic deposition (EPD) [ and their hardness, wear and corrosion resistances [ were examined. After studying the morphology of the coatings and finding the optimum conditions for uniform coating, in order to improve the mechanical properties as well as resistance to corrosion, sintering was performed. The Ni/SiO2nanocomposite coatings show excellent hardness (~376 HV), reduced Youngs modulus (~180 GPa), contact stiffness (~110 μN/Nm) as well as the wear and corrosion resistances which are considered in the different SiO2concentrations and particle sizes. In addition, by controlling the size of the SiO2particles, in optimum coating voltage and proper time duration, hardness and wear resistance of nanocomposite coatings were controlled.

scholarly journals Low Frictional MoS2/WS2/FineLPN Hybrid Layers on Nodular Iron

Coatings ◽  
2020 ◽  
Vol 10 (3) ◽  
pp. 293 ◽  
Author(s):  
Pior Kula ◽  
Robert Pietrasik ◽  
Sylwester Pawęta ◽  
Adam Rzepkowski
Keyword(s):  
Wear Resistance ◽  
Cast Iron ◽  
Composite Coatings ◽  
Nodular Cast Iron ◽  
Iron Nitrides ◽  
High Wear Resistance ◽  
Low Friction ◽  
Nodular Iron ◽  
Hybrid Layers ◽  
Interesting Alternative

The paper presents the new concept of low frictional hybrid composite coatings on nodular cast iron. The structure of it is multilayer and consists of MoS2 and/or WS2 nanoinclusions embedded in the iron nitrides’ zone and relatively deep hard diffusion zone. It offers a low friction coefficient as well as high wear resistance of coated parts. The details of technology as well as the mechanism of layer’s growth have been presented and discussed. The presented technology may be an interesting alternative for chromium-based galvanic coatings of piston rings made of nodular iron using Cr6+.

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