wear behavior of basalt filled low density polyethylene composites

Wear Behavior of Basalt Filled Low Density PolyethyleneComposites

Akin Akinci & Senol Yilmaz & Ugur Sen

Received: 5 February 2011 /Accepted: 7 June 2011 /Published online: 14 June 2011# Springer Science+Business Media B.V. 2011

Abstract The friction and wear performance of pure LDPE and 10%, 30%, 50% and 70%basalt filled (by wt) LDPE composite were comparatively evaluated under dry slidingconditions. Wear tests were carried out at room temperature under 5, 10 and 20N loads andat 0.5, 1.0 and 1.5 m/s sliding speeds. The coefficients of friction of the composites weresignificantly influenced with increase in basalt content. Friction coefficient of the LDPEwas getting decreased from 0.51 to 0.13 with increase in basalt content, depending onapplied loads and sliding speeds. The results show that the wear rates for pure LDPE andbasalt filled composites increase with increasing loads and sliding speeds. The wear rates ofthe basalt filled composites were significantly affected from the basalt content. Wear rates ofthe LDPE was decreased from 2.596×10−3 to 6.8×10−5 mm3/m with increase in basaltcontent, depending on applied loads and sliding speeds.

Keywords Low density polyethylene . Basalt . Friction . Wears

1 Introduction

In the last few decades, polymeric materials have been widely used in industry. Some ofthese materials, especially thermoplastics (polyethylene (PE), polypropylene (PP) etc.),have shown a great improvement in their mechanical properties by the use of the hot diedrawing technique. The main advantage of polymers from a tribological point of view istheir reasonably low rate of wear [1]. But their applications have been greatly limited fortheir mechanical properties. Therefore, various filler reinforcement of polymers has beentried. [2].

Appl Compos Mater (2012) 19:499–511DOI 10.1007/s10443-011-9208-9

A. Akinci (*) : S. Yilmaz : U. SenFaculty of Engineering, Department of Metallurgical and Materials Engineering, Sakarya University,Esentepe Campus, 54187 Sakarya, Turkeye-mail: [email protected]

S. YilmazTubitak-MAM, Material Institute, Gebze, Kocaeli, Turkey

Low density polyethylene (LDPE) has a very complex molecular structure despite thefact that it consists of only one monomeric unit, i.e. ethane [3, 4]. Polyethylene hasexcellent electrical properties making it widely being used as insulator. The low-densitypolyethylene consists of highly branched low crystalline units used with the formula(CH2CH2)n [5]. Due to its high cross linking yield and low degradation, polyethylene (PE)is a material commonly used for the radiation processing of items such as heat shrinkabletubes and films [3]. All these have enabled the extensive use of the so-called “technical”and “high performance” polymers in applications of high technological content [6]. Theadhesive properties of a low-density polyethylene (LDPE) are used in automotiveapplications (steering wheels) for obtaining the optimum mechanical performance. All thisfavors the growing use of these materials in technological sectors such as medicine,automotive, aerospace, electronics, etc. The LDPEs are used alone or, in most cases,combined with other materials (mainly metallic and polymer) such as other films, foams,membranes, coatings of electrical wire, pipelines, bus and home floors etc. to formlaminates [7].

LDPEs have good toughness, flexibility, low temperature resistance, clarity in film,and relatively low heat resistance, as well as good resistance to chemical attack. LDPEhas a good balance of mechanical and optical properties with easy process ability andlow cost. The thermal properties of LDPE include a melting range with a peak meltingpoint of 106–112°C. Its relatively low melting point and broad melting rangecharacterize LDPE as a plastic that permits fast, forgiving heat-seal operations. Theglass-transition temperature Tg of LDPE is well below room temperature, accounting forthe plastic’s soft, flexible nature [8].

In many applications polymers with inorganic fillers are used to improve thermal,mechanical, magnetic, electric and other properties [9]. In comparison to metals, generallyunfilled polymers have low wear resistance. One of the main important characteristics ofmaterials is wear and friction. Wear is defined as the damage to a solid surface, generallyinvolving progressive loss of material, due to relative motion between that surface andcontacting substance or substances [10]. Polymers and composites form a very importantclass of tribo-materials and are used where components are supposed to run without anyexternal lubricants [11]. Polymers and composites are extensively used in wear situationsdominated by various types of abrasive mechanisms. In the case of polymers, the wearperformance of pure polymer is not always very satisfactory and needs to be modified [12].

Basalts are fine grained compact rocks and tuffs, which are the major constituent ofocean islands and common component of the continental masses as well [13–16]. Basaltbase materials have superior abrasion, wear and chemical resistant materials. They can beused wherever the transport of material causes mechanical or chemical abrasion as well asmineral wool for heat, noise and fire insulation. Basalt finds wide application in industryas abrasion, wear and chemical resistant materials. It can also be used as filler material forproduction of the polymer matrix composites [13–15]. As a result of all theseexplanations, the advantages of basalt as filler material are cost effective, wear resistant,hard and well suitable filler material for polymer composite materials according tosynthetic materials like alumina, silica, zircon etc. In addition, basalt has a fine grainstructure and includes very hard phases like diopside and augite. Therefore, it is muchsuitable for using as a filler material for polymer composites according to natural rockslike calcite, wollastonite etc.

In the present work, test materials have been prepared a series of filled LDPE compositeswith basalt filler (10–70 wt.%) to study the tribological effect of the filler content. The aimof this work was to study the effect of the basalt on wear and friction behavior of the LDPE.

500 Appl Compos Mater (2012) 19:499–511

2 Experimental

The polymer matrix material that used in this study is a commercial grade LDPE suppliedby Turkish Polymer Industry. Natural basalt volcanic rocks obtained from Konya desert ofthe Middle Anatolia region of Turkey were used in the composites.

Basalt, composition given in Table 1, was ground using a ring grinder and sieved tobe in the range of 170–200 mesh the particle size for the polymer matrix composites.Basalt used in the study includes augite and diopsite phases. These phases generallynamed as diopsidic augite. The particle size distributions of the basalt are given inTable 2. The pre-cursors of the composite samples were prepared to use a single screwedextruder. In this process, the temperature profiles of the triple heaters of the extruderscrew barrel were 165°C, 175°C and 180°C from hopper to die, respectively. For theproduction of basalt filled LDPE polymer samples, an injection apparatus having tripleheaters at the temperatures of 165°C, 175°C and 180°C was used. Injection and moldingwere realized into the molding at the fixed temperature of 30°C under the pressures of5 MPa and 9 MPa for 30 s, respectively. The friction and wear tests were realized usingpin-on-disk arrangement with the standards of ASTM G 99. The dimensions of the weartest samples are 60 mm length and 6 mm diameter, and flat ended. AISI 4140 steel discwas used as a counter material which has 59 HRC hardness and 1.2 μm averageroughnesses (Ra). Wear tests parameters are given in Table 3. Wear rates (WR) of the wornsamples were obtained using Eq. 1.

WR ¼ $V

l¼ $m d=

lð1Þ

Where, ΔV; volumetric wear loss, l; sliding distance, Δm; mass loss and d; density.ASTM D 792 standard was used for the density measurements. The hardness tests were

performed on Instron S1 Durotech, digital shore D scale hardness tester with using thestandard of ASTM D 2240.

The contour diagrams are very important for practical application in the determination ofprocess parameters for desired test conditions or for determination of the test results fordesired process parameters. In the present study, contour diagrams were drawn for frictioncoefficient and wear rates of the basalt filled LDPE composites. Also, the contour diagramsderived can be used for two purposes: (i) to predict the friction coefficient and wear rateswith respect to the sliding speeds and basalt content of the composites, (ii) to determine thevalue of sliding speeds and basalt content of the composites for obtaining a predeterminedthe friction coefficient and wear rates.

Compounds Wt.%

SiO2 45.88

Al2O3 18.20

Fe2O3 9.95

CaO 9.28

MgO 6.62

K2O 1.64

Na2O 4.76

P2O5 1.04

LOI 2.63

Table 1 Chemical compositionof basalt used in the study

Appl Compos Mater (2012) 19:499–511 501

3 Results and Discussion

Figure 1 presents the variation of coefficient of frictions of LDPE, LDPE-10 wt.% basalt,LDPE-30 wt.% basalt, LDPE-50 wt.% basalt and LDPE-70 wt.% basalt versus slidingdistance at the sliding speed of 1 m/s and under the loads of 10N. For all basalt filled LDPEcomposites, the coefficient of friction starts with a running-in period up to 40 m, followedby steady state period. It is believed that within the running-in period, crinkles are formedon the surface of the polymer and polymer composites. But within the steady state period,these crinkles disappear and the wear debris covers the surface, leading to steady statefriction values. This is in good agreement with literature [17, 18].

Figure 2 reveals the variation of the coefficients of friction of LDPE and the basalt filledLPDE composites depending on basalt content and applied loads at the sliding speeds of1.0 m/s. The coefficient of friction of LDPE decreases with increase in basalt content ofbasalt filled LDPE composites up to 30 wt.% addition. The coefficient of friction of basaltfilled LDPE composite showed steady-state behavior, over 30 wt.% basalt in thecomposites. There is a 75.5%, 73.9% and 68.8% average decrease in the coefficient offriction values with addition of 30 wt.% basalt to the LDPE polymer under the loads of 5N,10N and 20N, respectively. In addition to that, it was found that a 300% increase in appliedload resulted in 30 wt.% average increase in the coefficient of friction of basalt filled LDPEcomposites. This is in agreement with the results obtained by Wang and Lee [18].

Figure 3 shows the variation of the coefficients of friction of LDPE and basalt filledLDPE composites depending on basalt content and sliding speed under the loads of 10N.There is a 68.6%, 73.9% and 75.2% average decrease in the coefficient of friction valuewith an addition of 30 wt.% basalt to the LDPE polymer at the sliding speeds of 0.5 m/s,1.0 m/s and 1.5 m/s, respectively. In addition, 200% increase in sliding speed (from 0.5 m/sto1.5 m/s) resulted in 51.1%, 55.6%, 19.2%, 9.4% and 11.4% for basalt free, 10%, 30%,

Particle size (μm) %

0–38 11.45

38–45 13.75

45–53 17.34

53–63 37.86

63–75 19.28

75–90 10.32

Total 110.00

Table 2 Particle size distribu-tions of basalt

Parameters (Units) Experimental conditions

Applied load (N) 5, 10, 20

Contact pressure (MPa) 0.177, 0.354, 0.707

Velocity (m/s) 0.5, 1.0, 1.5

Temperature (°C) 23±2

Humidity (%) 65±1

Sliding distance, l (m) 1000

Surface roughness, Ra (μm) 0.28

Repeated test for each sample 3–5

Table 3 Experimental processparameters of wear tests


50% and 70% basalt filled LDPE, respectively. It is possible to claim that the increase in thebasalt content and sliding speeds caused to decrease of the friction coefficient of LPDEcomposite, see Fig. 3. Myshkin et.al [19] explained that friction conditions to affect thecoefficient of friction of the polymers. Polymers as viscoelastic materials are very sensitiveto frictional heating. It is well known that friction is a typical dissipative process in whichmechanical energy is converted into heat. The thermal state of friction contact is frequently

Basalt content, wt.%

0 10 20 30 40 50 60 70

Coe

ffici

ent o

f fric

tion,

µ

0,0

0,1

0,2

0,3

0,4

0,5

5 N10 N20 N

Fig. 2 Variation of coefficient of friction with basalt content for 5 N, 10 N and 20 N (sliding velocity of 1 m/s)

Sliding Distance, m

0

Coe

ffici

ent o

f fric

tion,

µ

0.0

0.2

0.4

0.6

0.8

LDPELDPE+10 wt.% BasaltLDPE+30 wt.% BasaltLDPE+50 wt.% BasaltLDPE+70 wt.% BasaltLDPE

LDPE+10 wt.% Basalt

LDPE+30 wt.% Basalt LDPE+50 wt.% Basalt LDPE+70 wt.% Basalt

100800600400200

Fig. 1 Variation of coefficient of friction with sliding distance for LDPE, LDPE+10%basalt, LDPE+30%basalt, LDPE+50%basalt, LDPE+70%basalt (applied load=10N; sliding velocity=1 m/s)


a decisive factor when evaluating the performance of a friction unit. It is clear from theFigs. 2, 3, 4 and 5 that the influence of basalt content of the LDPE composite is muchhigher than that of the applied load and sliding speed. It is believed that, basalt free LDPEexhibited adhesion to the steel counter face in the sliding test because of low hardness, lowsoftening temperature (<100°C) and high pressures [8]. Increase in basalt content of theLDPE composite resulted to increase of the polymer hardness (see Table 4) and pressurestrength. Yang et al. [20] studied on different polymer composites and indicated that, thehardness of the polymer composite increases with an increase in ceramic based fillercontent. And so, friction resulted from the deformation of material in the actual spotsdecreases with increase in basalt content. In the friction test, basalt filled LDPE compositesstraightened up with the performance of basalt particles. It is possible that the heatgenerated from the sliding condition softens to the LDPE matrix and swears to the contactarea and behaves like a lubricant and so caused to the decrease of the coefficient of friction.

Figures 4 and 5 indicate that the coefficient of friction value depending on basalt contentof the LDPE composite, applied loads and sliding speed. These maps has the scope tochoose the correct working condition for suitable sliding conditions of the composite andthe possibility of controlling the coefficient of the friction of this composite by selecting thesuitable compound mix, applied load value and sliding speed (Figures 4 and 5). It should benoticed that the maps in Figs. 4 and 5 able us to choose the correct combination of materialcomposition, sliding speed and applied load value to reach to minimum coefficient offriction. It is possible to use the graphs for production of the results untested conditions inthe range of test values or to use for the pre-determination of the test conditions fordetermined friction coefficient.

Depending on basalt content and applied loads at the sliding speeds of 1.0 m/s, thevariation of the wear rates of LDPE and basalt filled LDPE composites were given inFig. 6. As it can be seen in Fig. 6 that the wear rates of LDPE polymer decreases with an


0 10 20 30 40 50 60 70

Coe

ffici

ent o

f fric

tion,

µ

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0.5 m/s1.0 m/s1.5 m/s

Fig. 3 Variation of coefficient of friction with basalt content for 0.5 m/s, 1.0 m/s and 1.5 m/s (applied loadsof 10 N)


increase in basalt content of basalt filled LDPE composites up to 30 wt.% addition. Thewear rates of basalt filled LDPE composite show a steady-state behavior over 30 wt.%basalt content. There is an average 85.1%, 91.5% and 90.7% decrease in wear rates withaddition of 30 wt.% basalt to the LDPE polymer under the loads of 5N, 10N and 20N,respectively. Additionally, 300% increase in applied load resulted in 92.2% average increasein the wear rates of the basalt filled LDPE composites.

The variation of the wear rates of LDPE and basalt filled LDPE composites usingsliding speed under the loads of 10N were illustrated in Fig. 7. It can be clearly seen inFig. 7 that there is a 91.5%, 90.6% and 93.2% average decrease in wear rates of 30 wt.%basalt filled LDPE composite at the sliding speeds of 0.5 m/s, 1.0 m/s and 1.5 m/s,respectively. In addition, a 200% increase in sliding speed resulted to 72.3% averageincrease in the wear rate of basalt filled LDPE composites. It is clear from Fig. 7 thatbasalt content of the LDPE composite has higher influence to wear rates according tosliding speed.

Figures 8 and 9 illustrate the changing of wear rates depending on basalt content of theLDPE composite, applied loads and sliding speeds, respectively. These maps has the scopeto choose the correct working condition for suitable wear resistance of the composite andthe possibility of controlling wear rates of this composite by selecting the suitablecompound mix, applied load value and sliding speed. It is also need to note that using mapsin Figs. 8 and 9 able us to choose the correct combination of material composition speedand load value to reach minimum wear rates.

0,10

0,10

0,10

0,25

0,25

0,25

0,25

0,20

0,20

0,20

0,20

0,15

0,15

0,15

0,15

0,40

0,40

0,35

0,35

0,35

0,35

0,30

0,30

0,30

0,30


0 10 20 30 40 50 60 70

Load

, N

6

8

10

12

14

16

18

20

Coefficent of friction, µ

Fig. 4 Contour diagram of coefficient of friction of filled LDPE composite depending on applied load andbasalt content, 1 m/s


It is also clear from the Figs. 6, 7, 8 and 9 that the influence on the wear properties ofbasalt content of the LDPE composite is much higher than that of the applied load andsliding speed. It is believed that, basalt free LDPE exhibited higher wear rates against steelcounter face in the sliding test, because of low hardness, low softening temperature andhigh pressures. Increase in basalt content of the LDPE composite resulted in the increase ofthe polymer hardness and pressure strengths of the LDPE-basalt filled composites. This isin good agreement with literatures [20, 21].

Figure 10 shows to the changing of the specific wear rates of the LDPE and itscomposites with basalt at the sliding speed of 1 m/s. As shown in the Fig. 10, specific wearrate decreases with increase in basalt content. Specific wear rate of 70 wt.% basalt filled

0,10

0,10

0,10

0,20

0,20

0,20

0,20

0,15

0,15

0,15

0,150,45

0,40

0,40

0,35

0,35

0,35

0,30

0,30

0,30

0,30

0,25

0,25

0,25

0,25


0 10 20 30 40 50 60 70

Slid

ing

spee

d, m

/s

0,6

0,8

1,0

1,2

1,4

Coefficient of friction,µ

Fig. 5 Contour diagram of coefficient of friction of filled LDPE composite depending on sliding speed andbasalt content, 10N

Table 4 Physical and mechanical properties of basalt filled LDPE

Basalt content (wt.%) Hardness (Shore D) Density (g/cm3)

LDPE, basalt free 45.50 0.94

10 48.00 1.01

30 49.70 1.17

50 55.30 1.42

70 68.70 1.81


LDPE composite is 98.31% lower than that of the pure LDPE. The more the basalt contentsof the basalt filled LDPE composites, the lower the specific wear rate resulted.

Figure 11a–e shows the optical micrographs of worn pin surfaces of pure LDPE, 30 wt.%and 50 wt.% basalt filled LDPE at the 1 m/s sliding speed under the load of 10N, and 30wt.%basalt filled LDPE at 0.5 m/s, 1 m/s and 1.5 m/s sliding speeds under the load of 10N. As it


0 10 20 30 40 50 60 70

Wea

r ra

te, m

m3 /m

0,000

0,002

0,004

0,006

0,008

0,010

0,012

0,014

0,016

0.5 m/s1.0 m/s1.5 m/s

Fig. 7 Variation of wear rate with basalt content depending on sliding speed for applied load of 10 N


0 10 20 30 40 50 60 70

Wea

r ra

te, m

m3 /m

0,000

0,002

0,004

0,006

0,008

0,010

0,012

5N10N20N

Fig. 6 Variation of wear rate with basalt content depending on applied load for sliding speed 1 m/s


can be seen in Fig. 11(a) that the worn surface of pure LDPE is smooth and includingtiny grooves. Figure 11(b) and (c) show worn surfaces of 30 wt.% and 50 wt.% basaltfilled LDPE pin tested at 1 m/s sliding speeds, and Fig. 11(d) and (e) give the wornsurfaces of the 30 wt.% basalt filled LDPE at 0.5 m/s and 1 m/s sliding speeds under theload of 10N, respectively. It was observed that basalt particles took place on the wornsurfaces and some tiny groves which is deeper than that of pure LDPE on the wornsurfaces of the basalt filled LDPE composites.

4 Conclusions

The following conclusions can be drawn from the present study; Coefficient of friction ofpure LDPE and basalt filled LDPE composites start with a running-in period up to 40 mfollowed by steady state period. Coefficient of friction of LDPE decreases with increase inbasalt content of basalt filled LDPE composites up to 30 wt.% basalt, and over 30 wt.%basalt content exhibit steady state behavior.

Increase in the applied load and sliding speed in the sliding tests resulted to increase incoefficient of friction of the pure LDPE and basalt filled LDPE composites. Wear rates ofbasalt filled LDPE composites decrease with increase in basalt content up to 30 wt.% andover 30 wt.% basalt content they exhibit steady state behavior. Increase in the applied load

0,002

0,002

0,002

0,0020,010

0,008

0,008

0,008

0,006

0,006

0,006

0,004

0,004

0,004

0,004


0 10 20 30 40 50 60 70

Load

, N

6

8

10

12

14

16

18

20

Wear rate, mm3/m

Fig. 8 Contour diagram of wear rate of filled LDPE composite depending on applied load and basalt content



0 10 20 30 40 50 60 70

Spe

cific

wea

r ra

te, m

m3 /(

N.m

)

1e-6

1e-5

1e-4

1e-3

Fig. 10 Variation of specific wear rate with basalt content for LDPE, LDPE+10 wt.%basalt, LDPE+30 wt.%basalt, LDPE+50 wt.%basalt, LDPE+70 wt.%basalt (sliding velocity=1 m/s)

0,002

0,002

0,002

0,0020,014

0,012

0,012

0,010

0,010

0,010

0,008

0,008

0,008

0,008

0,006

0,006

0,006

0,006

0,004

0,004

0,004

0,004


0 10 20 30 40 50 60 70

Slid

ing

spee

d, m

/s

0,6

0,8

1,0

1,2

1,4

Wear rate, mm3/m

Fig. 9 Contour diagram of wear rate of filled LDPE composite depending on sliding speed and basalt content


and sliding speed in the sliding tests of the pure LDPE and basalt filled LDPE compositesresulted in an increase in wear rates. The more the basalt contents of the LDPE+basaltcomposite, the lower the specific wear rate of the LDPE+basalt composite resulted. Wornsurfaces of pure LDPE and basalt filled LDPE composites exhibit tiny grooves and basaltfilled LDPE composites includes tiny scratches on the worn surface which is deeper thanthat of the pure LDPE included.

Groove

Basalt particle

Micro cutting

(a) (b)

(c)

(e)

(d)

Fig. 11 Optical micrographs of worn surfaces of (a) pure LDPE, (b) LDPE+30 wt.% basalt, and (c)LDPE+50 wt.% basalt, at 1 m/s sliding speed, (d) LDPE+30 wt.% basalt at 0.5 m/s sliding speed and (d)LDPE+30 wt.% basalt at 1.5 m/s sliding speed under 10 N load


Acknowledgments The authors would like to thank to Sakarya University-Scientific Research ProjectsCoordination (SAU-BAPK) for the research project numbered 2007.01.08.004 and Plascam Company ofTurkey for the production of the test samples. The authors are grateful to Sakarya University, Faculty ofEngineering, Assoc. Prof. Dr. Ali Osman KURT and Prof. Dr. Cuma BINDAL, the Head of the Department ofMetallurgical and Materials Engineering for supporting and checking of the work.

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wear behavior of basalt filled low density polyethylene composites

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