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Wear tests were
performed with PTFE+Al2O3 nanocomposites on various manufactured
surfaces to determine whether or not the wear resistance of these
nanocomposites is a strong function of surface preparation. Grade
304 stainless steel counterfaces having four different surface finishes
were used: electropolished (Rq 88 nm), lapped (Rq 161 nm), wet-sanded
(Rq 390 nm), and dry-sanded (Rq 578 nm). PTFE+Al2O3 nanocomposites
made from powders of roughly 2-20 um PTFE (matrix) and ~44 nm Al2O3
(filler) were prepared at filler weight percentages of 0%, 1%, 5%
and 10% and tested on each surface finish. Additionally, 5 wt.%
44 nm nanocomposites were compared to identically prepared 5 wt.%
80 nm and 500 nm Al2O3 filled PTFE composites on each surface. Friction
coefficients were between 0.12 and 0.19 and wear rates decreased
from K=810x10-6 mm3/Nm for the 5 wt.% 500 nm alumina filled PTFE
on the dry-sanded surface to K=0.8x10-6 mm3/Nm for the 5 wt.% 80
nm filled composite on the lapped surface. It was found that the
minimum wear rate occurred on the lapped counterface for every composite,
and the wear-rate is a strong function of the transfer film thickness
and morphology.
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