Bulletin of Materials Science

INVESTIGATION OF TRIBOLOGICAL PROPERTIES OF FLY ASH BLENDED

POLYMER COMPOSITES
--Manuscript Draft--

Manuscript Number: BOMS-D-18-00823

Full Title: INVESTIGATION OF TRIBOLOGICAL PROPERTIES OF FLY ASH BLENDED

POLYMER COMPOSITES

Article Type: Original Research

Keywords: fly ash; polymer composite; scratch; Wear; friction.

Corresponding Author: Ibrahim GUNES, Assoc. Prof.

Afyon Kocatepe University
Afyonkarahisar, TURKEY

Corresponding Author Secondary

Information:

Corresponding Author's Institution: Afyon Kocatepe University

Corresponding Author's Secondary

Institution:

First Author: Ibrahim GUNES, Assoc. Prof.

First Author Secondary Information:

Order of Authors: Ibrahim GUNES, Assoc. Prof.

Tayfun UYGUNOĞLU

Atilla EVCİN

Bahri ERSOY

Atila Gürhan ÇELİK

Order of Authors Secondary Information:

Funding Information:

Abstract: In this study, it was studied that the abrasion resistance and characteristics of polymer
composites with fly ash (FA). The polymer composites were produced with epoxy
based resin and FA as mineral additive. FA was added to mixtures in different ratio by
replacing the resin from 0 to 30% by weight. Composites were cured in air condition
and they were de-molded after 24 hours. They gain ultimate strength after 7 days.
Therefore, abrasion tests were performed on 7 aged specimens. Abrasion
characteristics of polymer composites were defined by pin-on-disc test for 500 m under
a dry friction condition at room temperature. Three types of loading conditions were
carried out as 5 N, 10 N 15 N and 30 N. The hardness and wear resistance values
increased with the increase in the content of fly ash. Showing the relationship between
wear rate and hardness, an equation with parameters dependent on load was
provided. There was an increase in the dynamic friction with an increase in the surface
roughness. In addition, dynamic friction was an increasing function of the wear rate.
The wear surfaces of the polymer composites were analyzed using scanning electron
microscopy. It was observed that the wear rate of the epoxy composites and pure
epoxy samples ranged from 17.82 to 172.96 mm3/Nm.

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TRIBOLOGICAL PROPERTIES OF FLY ASH BLENDED POLYMER

1
2 COMPOSITES
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6 Ibrahim GUNES1*, Tayfun UYGUNOĞLU2, Atilla EVCİN3, Bahri ERSOY4, A. Gürhan
7 ÇELİK5
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10 1
Afyon Kocatepe University, Metallurgy and Materials Engineering Department, Afyonkarahisar-TURKEY
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12 Afyon Kocatepe University, Civil Engineering Department, Afyonkarahisar-TURKEY
13 3
Afyon Kocatepe University, Materials Science and Engineering Department, Afyonkarahisar-TURKEY
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15 Afyon Kocatepe University, Mining Engineering Department, Afyonkarahisar-TURKEY
16 5
Department of Civil Engineering, Engineering Faculty, Giresun University, 28200, Giresun, Turkey
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19 Tel: +90 272 228 14 47 Fax: +90 272 228 14 49
20 E-mail: igunes@aku.edu.tr
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27 Abstract
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31 In this study, it was studied that the abrasion resistance and characteristics of polymer
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33
composites with fly ash (FA). The polymer composites were produced with epoxy based resin
34 and FA as mineral additive. Mixtures of different ratio by replacing the FA were added to the
35
36 resin from 0 to 30% by weight. Composites were cured in air conditioning and they were de-
37
38 molded after 24 hours. They gain ultimate strength after 7 days. Therefore, abrasion tests were
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40 performed on 7 aged specimens. Abrasion characteristics of polymer composites were defined
41
42 by pin-on-disc test for 500 m under a dry friction condition at room temperature. Three types
43
of loading conditions were carried out as 5 N, 10 N 15 N and 30 N. The hardness and wear
44
45 resistance values increased with the increase in the content of fly ash. Showing the
46
47 relationship between wear rate and hardness, an equation with parameters dependent on load
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49 was provided. There was an increase in the friction coefficient with an increase in the surface
50
51 roughness values. In addition, dynamic friction was an increasing function of the wear rate.
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53 The wear surfaces of the polymer composites were analyzed using scanning electron
54 microscopy. It was observed that the wear rate of the epoxy composites and pure epoxy
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56 samples ranged from 17.82 to 172.96 mm3/Nm.
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59 Keywords: fly ash; polymer composite; scratch; wear; friction.
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 1. INTRODUCTION
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3 Fly ash produced during coal burning for energy production is an industrial side
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5 considered as an environmental contaminant [1]. It is generated in million tons worldwide due
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7 to heavy industrial growth and a very few percentage is reused in different purposes. This
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9 large amount of industrial waste can cause significant environmental and ecological problems
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if not properly handled. Due to the ecological and economical importance, research has been
12 conducted around the world on the potential reuse and effective use of these wastes. [2]. The
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14 problem of fly ash disposal is expected to get worse as the demand for energy grows. The
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16 main use of fly ash is in making of Portland cement, road embankment and fly ash bricks.
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18 Beyond these large scale applications, fly ash hasn’t been used in product development and
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20 automobile industries which may play an important role in its reuse. Epoxy resin is a cheap
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semi viscous fluid which becomes a strong matrix material when a ceramic filler like fly ash
23 is used in it. Different types of ceramic, metal and bio materials are used as reinforcement in
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25 form of fibre or particle reinforcement. Filler material helps in increasing mechanical, thermal
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27 and tribological properties and simultaneously helps in reduction of cost of the component.
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29 Various researchers have used alumina and silica in polypropylene and polyethylene. But very
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31 few attempts have been made to use the cheap materials like rise husk, coir, jute fibre and
32 even chicken feather [3].
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35 Tribology is an important parameter while characterizing any material as it is related
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37 to the loss of material at the application area. The presence of hard reinforcement phases,
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39 particulates, fibres or whiskers has endowed these composites with good wear behavior
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41 properties. Under the loading condition the wear rate increases rapidly as the temperature due
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to frictional force matches with the material’s melting temperature [4,5]. Hence, to enhance
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44 the life of the part there must be lowest possible amount of wear during the use of the
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46 material. So, higher loading condition produces higher working temperature with increment in
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48 wear and lead to speedier substitution of parts [6]. Light weight polymer matrix composites
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50 like glass fiber and carbon fiber are the most suitable materials for weight sensitive
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52 application in aerospace and automobile industries due to its high strength and low erosion
53 rate [7]. In this view, the present work has been focussed on fabricating fly ash epoxy
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55 composite and its sliding wear test has been carried out at various treatment conditions to
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57 evaluate at which condition the product is sustaining minimum wear. Wear test has been
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59 carried out in three different treatment conditions like normal atmospheric condition, oven
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 treatment and micro oven treatment condition. Duration of curing in oven or micro oven has
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2 been determined by varying the temperature and duration of curing in a trial basis and
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optimized condition is chosen taking mechanical strengths into consideration. Prior to the
5 tribological experiment, the optimized oven treatment condition is found to be 30 minutes at
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7 1200c in oven and 5 min in micro oven at 60% of power flow. The DSC analysis curve shows
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9 the variation in enthalpy due to the treatment. In this present research work, effort has been
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11 made to increase the surface and overall property of the polymeric sample and compare it
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13 with the normal curing conditioned sample. Various researchers have explained the impact of
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fortification volume percentage, sliding conditions (time, distance, speed etc.) and applied
16 load that impacts the dry sliding wear of the composites [8,9].
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19 In general, studies take into account to enhance the tribological properties of polymer
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21 materials [10-14]. Epoxy resins are the most commonly used thermosetting plastics in
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23 polymer matrix composites and do not give reaction products when they are hardened and
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cause low hardening tensile strength. They also have good adhesion to other materials, good
26 chemical and environmental resistance, good chemical properties and good insulation
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28 properties. In this study, particularly, it was investigated that the influence of fly ash addition
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30 as filler on wear and friction characteristics of epoxy composite.
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2. EXPERIMENTAL STUDIES
37 2.1. Materials and sample preparation
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39 The fly ash (FA) used in the study was provided by the Tunçbilek Thermal Power
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41 Plant in Tavşanlı/Kütahya. It’s maximum particle size was 113.78 µ. Chemical component of
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43 waste is presented in Table 1.
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45 Commercially available epoxy resin along with hardener was used as matrix material
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in fabrication of different specimens. Epoxy resin has modulus of 3.42 GPa, and possess
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48 density of 1100 kg/m3. Mixing ratio (by weight) was used as indicated for the processing of
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50 epoxy resin (4 parts) and hardener (1 part). The required mixture of resin and hardener (Table
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52 2) were made by mixing them in parts in a beaker by stirring the mixture in a beaker by a rod
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54 taking into care that no air should be entrapped inside the solution. The polymer matrix
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56 composite was produced at room temperature. The requisite components of the resin,
57 hardener and FA were thoroughly mixed and the mixture prepared in this way was transferred
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59 to the mold cavity covered with the separator. Steel molds of Ø50 mm size were used for
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 casting of polymer matrix composite specimens. The curing was carried out at room
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2 temperature for about 24 hours. After hardening, the specimens were removed from the
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molded.
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7 2.2. Wear Tests on polymer composites
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9 To perform friction and wear of epoxy based samples, scratch tests were performed by
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11 using a ball-on-disc test device. In the abrasion tests, WC-Co balls with a diameter of 8 mm
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13 and an average hardness of 1895 HV were used. By using a separate abrasive element in each
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experiment, faults resulting from the corruption that may occur on the surface of the abrasive
16 element have been removed. The abrasion tests carried out in the ball-disk system were
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18 carried out under dry friction conditions, at room temperature, under loads of 5, 10, 15 and
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20 30N, at a shear rate of 0.3 m/s and a distance of 500 m. At the end of the wear test, the
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22 abrasion volumes of the specimens were calculated with data aid obtained from the so-called
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24 rugosimeter; is obtained at the end of the multiplication of the wear cross-sectional areas with
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the circumference of the formed wear trace. The rate of wear was calculated by dividing the
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27 amount of weared volume of the applied load and the slip distance.
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29 Friction coefficients of weared samples depending on sliding distance were obtained
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31 through a friction coefficient program.
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35 3. RESULTS AND DISCUSSIONS
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37 3.1. Surface roughness
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39 Figure 1 shows the surface roughness values of no added the waste material and added
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41 polymer composites. The surface roughness values were obtained close to each other in
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43 samples that control and with low fly ash material content. However, in samples with high
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45 volume FA content, the surface roughness is lower than FA0 specimen.
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48 3.2 Friction coefficient and wear rate
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50 Friction coefficients at different load are presented in Figure 2 for control and FA
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52 containing samples. While the lowest friction coefficient is obtained in FA0 samples as 0.39,
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54 it was increased to 0.53 in 30% of FA containing series. Use of FA in polymer composites
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56 provides higher friction coefficient when compared to control series. The friction coefficient
57 of all the series are increased by increasing of load.
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 Wear rate of polymer composites are given in Fig. 3 for 5, 10, 15 and 30N depending
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2 on FA content. As seen from the Fig. 3, wears of composites decreased by increasing the
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content of on FA. The highest wears were obtained for control series at each loading
5 conditions. The range of wear varied from 59.64x10-4 to 17.82x10-4 mm3/Nm at 5N, from
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7 80.13x10-4 to 36.75x10-4mm3/Nm at 10N, from 119.14x10-4 to 42.87x10-4mm3/Nm at 15N,
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9 from 172.96x10-4 to 60.12x10-4 mm3/Nm at 30N depending on fly ash content. In other words,
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11 there was about 2.87 times enhancement in wear resistance of fly ash composites at 30 N by
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13 increasing of waste content. Increase of FA addition ratio resulted with decrease of wear rate.
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This means that addition of FA makes the polymer material harder and also changes the
16 character of the surface. Wear strength is higher in high FA ratio than in low FA ratio due to
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18 more homogeny distribution of particles with high resist to abrasion. On the other hand, when
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20 the wear loading value was considered, the wear rate for all specimens increased with load
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22 regardless of FA ratio. The wear rate increased with an increase of load from 5 to 30N due to
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24 increase friction of and abrasion on surface of fly ash samples.
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One of the important findings of this study was relationship between hardness and
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27 wear rate for epoxy based and FA containing polymer composites (Figure 4). The hardness
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29 values of the samples increase with increasing FA content. For each load, wear resistance
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31 increases with increasing hardness. The related equations are given in the appendices in Fig.
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33 4. The coefficient of R2 is very close to 1.0 for each loading condition, the highest value
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35 being 30 N (R2 = corresponds to the perfect fit).
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37 The calculated regression functions can be seen in Fig. 5 to facilitate the analysis of
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39 the surface quality on the tribological properties of the examined epoxy-based polymer
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41 composites. This figure shows the dependence of the friction coefficient to surface roughness.
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43 The relationship between surface roughness and friction coefficient are lower at 5N (R=0.948)
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45 than 30N (R=0.994) loading condition. These results show that there is better relation
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between friction and surface roughness at high loadings.
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49 For FA blended epoxy based polymer composites, the relationship between the friction
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51 coefficient and wear rate is presented in Fig. 6. Suitable linear relation is developed between
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53 friction coefficients and wear rate, regardless of waste material content. The relation was
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55 found with correlation coefficient (R) of 0.927. As a function of wear rate, friction coefficient
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of FA blended polymer composites can be determined by:
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60 Fc= 0.0103Wr+0.164 (2)
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62 5
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 1
2 Where, Wr is wear rate; and Fc is friction coefficient.
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5 The wear SEM micrographs of epoxy composites after tribometry for various FA
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8 concentrations are shown in Figure 6. The hardness values of the samples are increased by
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10 increase of FA content. So, the wear resistance is increased when compared to control
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13 specimens due to high degree of hardness values of FA blended polymer composites (Fig. 7a-
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15 d). Increase of load provides that the ball moves over a wear border. The wear border makes
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the movement of the ball more difficult at high loading condition (see Fig. 7); now the
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20 indenter moves across the entire surface of each region [15-17]. As a result of the wear of the
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22 pure epoxy sample, tearing on the surface occurred (Fig. 7a). The wear tests in the added fly
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25 ash specimens, scratches, delamination wear, abrasive and adhesive wear occurred on the
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27 surface. As the fly ash additive ratio increases, the wear depth decreases. A high friction
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30 results, in fact even higher than friction values for pure components [18-20]. The hardness
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32 values of the samples are increased by increase of FA content. So, the wear resistance is
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35 increased when compared to control specimens due to high degree of hardness values of FA
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37 blended polymer composites.
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43 4. CONCLUSIONS
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46 The objective of this report has been to describe the tribological properties (Friction
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48 and wear characterization) of epoxy based polymer composites as well as the role of how fly
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50 ash additives can enhance the polymer composites properties. The following conclusions may
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52 be derived from the present study:
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54  The hardness values of samples are increased by using fly ash when compared to pure
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56 epoxy. The fly ash ratio increased surface roughness values.
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58  The surface roughness values were obtained close to each other in samples that control
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60 and with low FA content. Use of FA in polymer composites provides higher friction
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 coefficient when compared to control series. The friction coefficient of all the series
1
2 are increased by increasing of load.
3
4  Wear strength is higher in high FA ratio than in low FA ratio due to more homogeny
5 distribution of particles with high resist to abrasion. There is about 2.87 times increase
6
7 in wear resistance of in samples with added fly ash at 30 N by increasing of fly ash
8
9 content.
10
11  There was a good correlation between hardness and wear rate; roughness coefficient
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13 of friction; for epoxy based and FA blended polymer composites, friction coefficient
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15 and friction coefficient are obtained respectively.
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 Increase of load provides the ‘border effect’ on the surface. The border effect leads to
18 increase of friction coefficient at higher loading conditions.
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20  In microstructure studies, FA particles were found homogeneously distributed in the
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22 epoxy matrix. The wear tests in the added fly ash specimens, scratches, delamination
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24 wear, abrasive and adhesive wear occurred on the surface. As the fly ash additive ratio
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26 increases, the wear depth decreases.
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28  Consequently, it was obtained that notable improvement in the wear resistance,
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30
friction coefficient and surface quality by using of FA in epoxy based polymer
31 composites.
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35
36 ACKNOWLEDGEMENT
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39 This research was carried out under project number 114M155 The Scientific and Technical
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41 Research Council of Turkey (TUBITAK).
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47 5. REFERENCES
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 TABLE CAPTIONS
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Table 1. Chemical content of Fly ash
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9
Oxide CaO2 SiO2 AI2O3 Fe2O3 K2O Na2O MgO LOI
10 Content, % 6.66 47.4 19.8 11.8 2.62 0.57 4.76 6.39
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19 Table 2. Composition of epoxy based polymer composites
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21 Mixture code Epoxy resin*, % Fly Ash, % Hardness (HD)
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23 FA0 100 - 84
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25 FA10 90 10 86
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27 FA20 80 20 88
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29 FA30 70 30 91
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31 *Epoxy resin was used with hardener (4:1)
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 FIGURE CAPTIONS
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5 Figure 1: The variations in the surface roughness values of polymer composites with fly ash.
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9 Figure 2: The variations in the friction coefficient values of polymer composites with fly ash.
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12 Figure 3: Wear rate of polymers depending on fly ash content.
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16 Figure 4: Relationship between hardness and wear rate of the composites in the inserts.
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20 Figure 5: Relationship between dynamic friction and surface roughness.
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23 Figure 6: Relationship friction coefficient and wear rate on polymer composites.
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27 Figure 7: The wear SEM micrographs of epoxy composites after tribometry for various FA
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29 content: (a) for pure epoxy, (b) for 10% FA, (c) for 20% FA, (d) for 30% FA.
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22 Figure 1. The variations in the surface roughness values of polymer composites with fly ash
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Figure 2. The variations in the friction coefficient values of polymer composites with fly ash
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Figure 3. Wear rate of polymers depending on fly ash content
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23 Figure 4. Relationship between hardness and wear rate of the composites in the inserts.
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22 Figure 5. Relationship between dynamic friction and surface roughness.
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23 Figure 6. Relationship friction coefficient and wear rate on polymer composites
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31 Figure 7. The wear SEM micrographs of epoxy composites after tribometry for various FA
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content: (a) for pure epoxy, (b) for 10% FA, (c) for 20% FA, (d) for 30% FA.
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Letters to the editor

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