24th International Colloquium Tribology - January 2024 229 Building Tribology Application Testing to Determine Wear and Characterization of Polymer-based Composites Abstract from Versiv™ Composites Michael Katzer 1* , David Rich 2 , Diarmaid Williams 1 1 Versiv™, Kilrush, Ireland 2 Saint-Gobain, Merrimack, USA * Corresponding author: michael.katzer@versivcomposites.com 1. Introduction Tribology testing is vital for understanding, optimising, and predicting the frictional behaviour, wear resistance, and overall performance of polymer-based composites. It aids in material selection, performance optimisation, design, failure analysis, quality control, and cost reduction, ultimately leading to enhanced product performance, durability, and sustainability. It finally is the base for the correct material selection for the individual use case. 1.1 Methodology Objectives At Versiv™ Composites, our approach is comprehensive in establishing a reliable testing process close to the application, to demonstrate how to improve coating formulations, determine carrier materials and develop polymer-based composite products with optimised wear and friction performance tailored to the individual use case. Developing testing methods using customer insights Versiv™ Composites has a long-standing relationship with our customer. We were approached to develop an improved product for friction applications in a solenoid valve and a printer. The goal for the solenoid application was to produce a version with similar durability (number of cycles) to the existing model but thinner in profile to increase magnetic force. The customer requested a specific thickness level, and the challenge centred on creating the right material to ensure friction performance remained consistent while meeting the specified lifetime expectation. For the low friction lining assigned to the printer, the aim was to create a material capable of a longer lifetime, while ensuring the lowest possible friction. This project enabled the customer to access a premium market segment by introducing a durable product designed to enhance energy efficiency through its low friction value. Developing an application test Following initial sampling we received negative feedback, due largely to a long feedback loop as we relied on customers to test in the applications. To address this, we opted to create an application test capable of mimicking various scenarios related to friction usage. We acquired a tribometer after which we had to figure out a) what the right physical counterpart is to test against our polymer composite material and b) what the right parameters (speed, pressure) are to get an accelerated test and c) how to quantify that for our materials. The initial phase focused on formulating an experimental procedure that considered the aforementioned key points. Picture 1: Scheme of the experimental procedure to develop the tribology application test Co-development process to quantify wear and identify of optimal mix for real-world application Partnering with the customer, several samples, that had previously seen the application, were used to understand the impact of different parameters on the material and ensure that it correlated with the outcome in real-world use. Through benchmarking different quantification methods, e.g., wear scares, cross-section images, positive and negative value results were established and assigned. These value qualities were analysed through optical profilometry, and microscope and SEM were used to quantify the different results with wear depth and impact on the material surface and structure. Using methods and tribometer to differentiate wear performance Using techniques to quantify wear, including measuring the depth and width of the wear pattern, helped gauge the impact, aligning it with the effects of the use cases on the composite polymer materials. Profilometry was then applied to ensure changes were noted and understood due to the use of glass fabric or rigid polymers as reinforcement. Cross-section pictures helped with the observation of the impact on the different components of the composite material. 230 24th International Colloquium Tribology - January 2024 Building Tribology Application Testing to Determine Wear and Characterization of Polymer-based Composites Picture 2: Wear pattern of different polymer composite materials Tribology development (tool) / understand setting impact on materials The tool is based on a stainless-steel ball with a diameter of 6,35mm based on standards for plastic polymeric materials. Different parameters, such as the modification of pressure (single digit Newton) and speed to mimic the different load scenarios in the application, were used to understand the effect of the various settings generated by the tribology machine. Relaying back the results of testing to build the better performance product The different sample materials used, such as Fluoropolymer-coated Polyimide or Glass fabrics provided several different outcomes depending on their composition. More detail was discovered about how each component, carrier material and coating of Versiv™ Composites can influence wear and friction performance. The team’s findings also included that incorporating reinforcement materials, such as texture variations and diverse compressibility methods, can greatly enhance friction performance. Learnings from the evolution of the products The learnings garnered from this customer co-development activity initiated an internal study on how to optimise wear and friction performance by modifying the polymeric composition of dispersions that are coated on our reinforcement materials. The knowledge available in the group around filler materials was used to determine our path forward. By using different thermoplastic materials in different ratios, an optimisation could be achieved. 2. Conclusion Through demonstrating how we developed and then processed materials through a specific test matrix, conclusive evidence is provided on how to improve coating formulations and the choice of base carrier materials. These formulations, optimised by fillers and coated on the application-specific carrier material, are fit for use in the development of products where optimised wear and friction performance is essential.