Processing Fiber‐Reinforced Polymers: Specific Wear Phenomena Caused by Filler Materials

Abstract

Fiber-reinforced polymers allow for the implementation of plastic materials in structural components. However, increasing incorporation of fibers up to 50 wt% causes accelerated component wear in injection molding machines. In particular, the barrel and screw in the compression zone suffer from increased wear. The abrasive fibers of the compacted polymer pellets in the solid bed protrude from the surfaces of the resin having an abrasive, brush-like behavior. A modified pin-on-disk testing system with specially designed polymer pins was used to emulate the described tribological system in laboratory scale. Through varying contact pressure, temperature, and surface modifications of the counterparts (blank or coated powder-metallurgical steel), abrasive wear as observed in industrial-sized extruder screws could be successfully simulated on a laboratory-scale testing system. Detailed investigations of the pins and disks highlighted that the glass fibers plow and cut the surface leading to abrasion as observed in the real field application. Temperature has been proven to be the most decisive driving force. Surface modifications such as protective physical vapor-deposited CrN coatings are effective against abrasive wear, clearly outperforming untreated steels. The presented pin-on-disk-test setup will improve screening of materials for extruders, thus enhancing the durability of injection molding machines.