Available online at www.sciencedirect.

com

ScienceDirect
Procedia Engineering 68 (2013) 694 – 702

The Malaysian International Tribology Conference 2013, MITC2013

Erosive wear behaviour of WC filled glass epoxy composites

N.Mohana*, C.R.Maheshaa, B.M.Rajaprakashb
a
Department of Industrial Engineering and Management, Dr.Ambedkar Institute of Technology, Bangalore-560 056, India.
b
Department of Mechanical Engineering, University Visweswaraya college of Engineering, Bangalore-560 001,. India.

Abstract

The effect of incorporation of tungsten carbide (WC) powders on erosive wear behaviour in glass fabric-epoxy (G-E)
composites was investigated and findings were analyzed. The vacuum-assisted resin infusion (VARI) technique was employed to
fabricate the composite specimens. The effect of different impact velocities (40 and 80 m/s) and impact angles (300 to 900) on
the performance of the wear resistance of the composites were measured. The results of erosive wear losses, impact angle, and
impact velocity and erosion rate of filled and unfilled glass-epoxy composites were analyzed and discussed. The influence of
impact angle on erosive wear of all composites shows brittle behaviour with a maximum erosion rate at 900 impact angle. The
WC filled G-E composite exhibited a lower erosion rate as compared to that of unfilled G-E composites. The worn surface
features of unfilled and filled G-E composites were examined using scanning electron microscopy (SEM) and results indicates
more severe damage to matrix and glass fiber in unfilled composite system as compared to WC filled composites.

©©2013
2013The
TheAuthors.
Authors. Published
Published by Elsevier
by Elsevier Ltd.Ltd.
Open access under CC BY-NC-ND license.
Selectionand
Selection and peer-review
peer-review under
under responsibility
responsibility of TheofMalaysian
The Malaysian Tribology
Tribology Society (MYTRIBOS),
Society (MYTRIBOS), Department
Department of
of Mechanical
Engineering,
MechanicalUniversiti Malaya,
Engineering, 50603 Kuala
Universiti Malaya, Lumpur,
50603Malaysia
Kuala Lumpur, Malaysia.
Keywords: Erosive wear, Glass, Epoxy, filler, Vacuum Assisted Resin Infusion Technique, Wear Mechanism.

Nomenclature

Į Impingement angle in degree

V Impact velocity of sand particles (m/s)
Ws Normalized erosion rate g/g
Wc Loss in weight of the composite material in grams
WEr Total weight of erodent used for erosion of each specimen grams

* Corresponding author. Tel.:+91- 080-23211505-Ext. 246 or 919060818100; Fax: +91- 080- 23217789.
E-mail address: drmohannagaraj@gmail.com

1877-7058 © 2013 The Authors. Published by Elsevier Ltd. Open access under CC BY-NC-ND license.
Selection and peer-review under responsibility of The Malaysian Tribology Society (MYTRIBOS), Department of Mechanical Engineering, Universiti
Malaya, 50603 Kuala Lumpur, Malaysia
doi:10.1016/j.proeng.2013.12.241
 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702 695

1.Introduction

Micromechanical interaction between original surface and solid particles causes a local damage of solid surface
with progressive loss of materials. The fiber reinforced plastics (FRP) composite parts, such as helicopter rotor
blades, aircraft operating in desert environments, high-speed vehicles, water turbines, pump impeller blades, aircraft
engine blades, missile components, canopies, radomes, and wind screens find extensive application in automotive
and aerospace sectors. The surface of these composite parts will be impacted by the solid particles contained in the
air, and those particles will destroy the original materials [1]. The improvement of the tribological properties of a
polymer with the incorporation of fibers/fillers is well known and it showed both positive and negative results on the
tribological properties of polymer matrix composites [2]. Crivelli Visconti et al. [3] studied a 6 vol. % of silica
(SiO2) and tungsten carbide (WC) filler filled glass fabric reinforced with epoxy matrix composites and they found
that tungsten carbide filled G-E composite shows excellent wear resistance. Commonly used filler materials in fiber
reinforced polymer composites are graphite, molybdenum disulfide, tungsten carbide and silicon carbide. Graphite
(Gr) and molybdenum disulfide (MoS2) possess self-lubrication properties and they are widely used in bearing liner
applications. Silicon carbide (SiC) has been extensively used in abrasive machining processes such as grinding,
honing, water-jet cutting and sand blasting due to its high hardness. The SiC and WC in epoxy imparts good wear
resistance and strength [4-7].

Recently N.Mohan et al. [8-9] in a study concluded that enhanced abrasive wear resistance and improved
fracture toughness can be obtained with the incorporation of tungsten carbide, tantalum niobium carbide and silicon
carbide filler into glass fabric-epoxy (G-E) composites. Keeping the above aspects in view, it is clear that there is a
lot of scope for the study of wear behaviour of polymer matrix composites. The present study was focus on the
preparation of glass fabric reinforced-epoxy composites reinforced with tungsten carbide (WC) as fillers in powder
form and to investigate the influence of this hard powder on erosive wear behaviour.

2.Experimental

2.1. Materials and Fabrication of composite specimens

A bidirectional E-Glass woven fabric 360 g/m2 was procured from M/s. Reva Composites, Bangalore, India.
The glass fabric of dimension 18 ȝm diameter was used as reinforcement. Bifunctional epoxy resin (LY 5052) and
room temperature curing cyclo aliphatic amine (HY 5052) (system) were obtained from M/s. HAM, India. The resin
is a clear liquid with viscosity at 250 C, 1000-1500 MPa and specific gravity 1.17g/cc. The hardener is a liquid and
its viscosity is 40-60 MPa and specific gravity 0.94 g/cc. The commercially available tungsten carbide in the ratio of
60:40 (WC) (Density of WC=15.6 g/cc, Size = 50-55 ȝm) was used as filler. The powders were procured from
M/s. Kennametal, Bangalore, India.

2.2. Fabrication of composite specimens

The composite fabrication consist of three steps: (a) mixing of the epoxy resin and filler using a mechanical
stirrer, (b) mixing of the curing agent with the filled epoxy resin, and (c) fabrication of composites. In the first step,
a known quantity of filler was mixed with epoxy resin using a ultrasonication process to ensure the proper
dispersion of filler in the epoxy resin. In the second step, the hardener was mixed into the filled epoxy resin using a
mechanical stirrer. The ratio of epoxy resin to hardener was 100:38 on a weight basis. In the last step, the epoxy
resin was manually smeared onto the glass fabric and the resultant composites were fabricated using the vacuum
assisted resin infusion (VARI) technique as described elsewhere [10] (Fig. 2). The composites were cured at room
temperature under a pressure of 14 psi for 24 h and it is post cured up to three hours at 1000 C The glass fiber:
matrix (epoxy): filler ratio was 60:36:4. The unfilled glass epoxy composites were designated as G-E and WC filled
G-E composites as Ta/NbC-G-E. The laminate of dimensions 300 mm x 300 mm x 2.6 + 0.2 mm was fabricated and
the specimens for the required dimensions were cut using a diamond tipped cutter. Density of the composites
696 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702

specimens was determined using a high precision digital electronic weighing balance of 0.1 mg accuracy by using
archimedes principle and the formulations measured density of the composites are listed in Table 1.

Fig.1. SEM image of Glass- epoxy composites after fabrication.

Table 1. Formulations of composite specimen with measured physical properties.

Specimen code Glass Matrix Filler Density Hardness

fibre (wt.%) (wt.%) (g/cc) Shore-D
(wt.%)

Glass fabric-epoxy composite 60 40 - 1.78 85

(G-E)

Tungsten Carbide filler filled

glass fiber- epoxy composite 60 34 4 1.81 87
(WC –G-E)

Fig. 2. Schematic of VARI setup: (a) Granite molding tool, (b) Dry glass fabrics, (c) peel ply and breather material (d) distribution
medium, (e) vacuum bag, (f) resin inlet, and (g) vacuum outlet.
 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702 697

2.3 Characterization Techniques

The solid particle erosion experiments were carried out as per ASTM-G76 standard on the erosion test rig (Fig.
3) [11]. The silica sand of size 150–280 ȝm are used as erodent (Fig. 4) which is fed constantly by a conveyor belt
feeder into the mixing chamber and then accelerated by passing the mixture through a convergent brass nozzle of 3
mm internal diameter. The setup is capable of creating reproducible erosive situations for assessing erosion wear
resistance of the composite samples. The erodent particles impact the specimen which can be held at different angles
with respect to the direction of erodent flow using a swivel and an adjustable sample clip. The velocity of the
eroding particles is determined using standard double disc method [12]. Erosive wear was measured by the weight
loss. The normalized erosion rate (Ws) was expressed in terms of equation (1);

Wc
WS W Er gm / gm (1)
Where, Wc is the loss in weight of the composite material and WEr is the total weight of erodent used for erosion
of each specimen. Wc is determined by weighing the sample before and after the erosive wear test using a digital
electronic balance, 0.1 mg accuracy. Each erosive wear test was performed twice and average values for wear loss
were calculated. The experimental detail is presented in Table 2.

Fig. 3. A Schematic diagram of erosive wear test rig.

698 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702

Fig. 4. SEM image of silica sand used as erodent.

Table 2 Erosion test conditions

Test parameters

Erodent Angular Silica sand

Erodent size (ȝm) 150-280
0
Impingement angle (Į, ) 30, 60, 90
Impact velocity (m/s) 40,80
Erodent feed rate (gm/min) 4

Test duration (min) 3

Test temperature RT
Nozzle to sample distance (mm) 10

Nozzle diameter (mm) 3

3. Results and Discussion

3.1 Erosion rate
The graphical plot of erosion rate versus impingement angles at two different velocities of filled and unfilled
composite systems is shown in Fig. 5(a)-(b). The erosion rate is controlled by three aspect factors (a) the operating
parameters such as the impact velocity and angle of incidence under the same operating temperature, (b) the
properties of the impingement particle such as shape, hardness and particle size and (c) the properties of the
materials [13-14]. In the present investigation, erosive wear behaviour of WC filled and unfilled glass-epoxy
composites influenced by the operating parameters and properties of the target materials.

The erosion behaviour of materials can be broadly classified as ductile and brittle depending on the variation of
the erosion rate (WS) with impingement angle (Į). Fig. 6 shows typical erosive wear diagrams as a function of
impact time and impingement angle. In reinforced composites ductile behaviour is characterized by maximum
erosion rate at low impingement angle (150-300) in this stage initially erodent particles may be embedded in the
target surface causing a weight gain. Brittle behaviour is characterized by maximum erosion rate at high
 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702 699

impingement angle (900) and weight loss increases linearly with time. This period is denoted as incubation period.
The maximum weight loss can be found at 900 and 300 impact angles for brittle and ductile erosions and semi-
ductile behaviour is characterized by the maximum erosion rate at an angle of impingement between 450 to 600 [15-
16].
4
11

G-E (a) 3.5

(b)
G-E
9

10-2 g / g
WC-G-E
10-3 g / g

3 WC-G-E

7
2.5

Erosion rate
Erosion rate

5
2

3 1.5

1 1
30 60 90 30 60 90
Impingement angle (Degree) Impingement angle (Degree)

Fig. 5. Erosion rate vs. angle of impingement of composites at (a) V=40 m/sec and (b) V= 80m/sec.

From Fig. 5 it was observed that maximum erosion occurs at 900 impingement angle for all the composites tested
and material characterized by brittle manner and higher weight loss. Minimum erosion rate was observed at an
impingement angle of 300 and lower erosion rate was observed. At this juncture, the authors are pleased to quote the
research work of Hager et al. and Karasek et al.[17-18] stated that there is no fixed trends are available which
correlates ductility or brittleness of materials with maximum or minimum angle of impingement. It is found that
some polymers erode in a ductile manner and some show evidence of both ductile and brittle characteristics. As
compared to unfilled composite WC filled composite shows minimum erosion rate at all experimental condition.
The presence of filler in composites resists the damage from hard silica erodent and hence lower weight loss was
observed (Fig.5). The lowest erosion rate of 0.0023 g/g was observed in WC filled glass-epoxy composites at
300 angle of impingement and at an impact velocity of 40 m/s and highest erosion rate of 0.037g/g was observed
in unfilled glass-epoxy composite at 900 angle of impingement and at an impact velocity of 80 m/s.

Fig.6. Ductile and brittle type of erosive wear behaviour schematically [23].
700 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702

From Fig. 7 it is obvious that erosion rate increases with increasing particle velocity but erosion rate of G-E
composite reduces only after incorporation of hard WC powder in G-E composite. However, erosion rate is strongly
affected by the variation of impingement angle of the particles and it is observed that the G-E composite gives
higher weight loss as compared to WC-G-E composites and material shows brittle mode of attack which is
evidenced by SEM images in Fig. 8. Incorporation of fibers/filler into matrix show both positive and negative effect
on mechanical and tribological properties [19-22].

Fig.7. Variation of erosion rate as a function of impact velocity of particle at 90 degree angle of erosion, V=80 m/sec.

3.2 Worn Surface Morphology

The surface morphology of the composites was examined using a scanning electron microscope (SEM) (S3000,
V-1, HITACHI). The basic erosive wear mechanisms of thermoset composites is matrix microcracking, fiber
matrix-debonding, fiber-breakage, and material-removal [23]. SEM image Fig. 8(a) indicates unfilled G-E
composite which depicts local removal of resin material from the impacted surface, which results exposure and
damage of the fibres to the erosive environment as seen in Fig. 8(a). Also, the SEM image reveal that solid sand
particles impact on the fibres and causes the fibre breakage, fibre cutting, matrix eroded, and detachment of broken
fibres from the resin matrix. The continuous action of erodent reduces the supporting strength of fibers on the
impacted surface and large numbers of fibers appear as breaks and extensively removed and hence the erosion rate is
more. As compared to unfilled composite in WC-filled composite (Fig. 8b) shows less exposure of fibres and only a
surface of the matrix eroded and lowest erosion rate was observed. This may be due to the restriction of debonding
between matrix and fibres due to the presence of hard powder and also prevents the fibre from damage during
erosion. At this juncture, the authors are pleased to quote the research work of Alok satapathy et al. [24–28]. Which
confirm that addition of fillers made in their present study also has brought in considerable improvement in erosion
resistance.

(a) (b)
 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702 701

Fig. 8 SEM images of (a) G-E and (b) WC-filled G-E composites eroded with silica sand size 150 to 280 mm at a Į=900 and V=40m/s (1000 x).

4. Conclusion

ƒ The incorporation of WC in G-E composites improves erosion resistance.

ƒ The influence of impingement angle on erosive wear of all composites under consideration exhibits brittle
erosive wear behavior with maximum erosion rate at 900 impingement angle.
ƒ SEM studies of worn surface support the involvement of wear mechanisms such as fiber breakage, fiber
cutting and eroded matrix.

Acknowledgement

Prof. & Dr.N.Mohan great full to the management of Dr.Ambedkar Institute of Technology, Bangalore, for
their distinguished help and financial support under TEQIP PHASE II for presenting and publishing this article.

References
[1] Friedrich, K. R. Reinicke, Z. Zhang, 2002. Wear of polymer composites Proceedings of the Institution of Mechanical Engineers, Part J:
Journal of Engineering Tribology 216, p. 415.
[2] Aziz, S. H., Ansell, M. P., Clarke, S. J., Panteny, Y,. S. R. 2005, Modified polyester resins for natural fibre composites, Composites
Science and. Technology, p. 65
[3] Crivelli Visconti, I., Langella, A., Durante, M., 2001. The wear behaviour of composite materials with epoxy matrix filled with hard
powder, J Appl Compos Mater. 8, p. 179–89.
[4] Suresha, B., Chandramohan, G., 2008, Three-body abrasive wear behaviour of particulate-filled glass–vinyl ester composites, J Mater Proc
Technol. 200, p. 306.
[5] Suresha, B., Chandramohan, G., Renukappa, M.N., Siddaramaiah, 2007. Mechanical and tribological properties of glass–epoxy composites
with and without graphite, J Appl Polym Sci. 103, p. 2472.
[6] Bijwe, J., Jhon Rajesh, J., Jeyakumar A., Gosh A., Tewari US. 2007. Influence of solid lubricants and fiber reinforcement on wear
behavior of polyethersulphone, Tribol Int. 33, p. 697.
[7] Chisholm, N., Mahfuzi, H., Rangari, V., Rodgers, R., Jeelani, S., 2004, Synthesis and mechanical characterization of carbon/epoxy
composites reinforced with SiC nano particles, NSTI Nanotechnol. 3, p. 302.
[8] Mohan, N., Natarajan, S., KumareshBabu, S.P., Siddaramaiah, 2010. Investigation on twobody abrasive wear behavior of silicon carbide
filled glass fabric–epoxy composites , J Min Mater. Charact Eng. 9, p. 23.
[9] Mohan, N., Natarajan, S., KumareshBabu, S.P., 2011. Abrasive wear behaviour of hard powders filled glass fabric–epoxy hybrid
composites, Materials and Design 32, p. 1704.
[10] Chisholm, N., Mahfuzi, H., Rangari, V., Rodgers, R., Jeelani, S., 2004. Synthesis and mechanical characterization of carbon/epoxy
composites reinforced with SiC nano particles, NSTI-Nanotech. 3, p. 302.
[11] Rajesh, J.J., Bijwe, J., Tewari, U.S., Venkataraman, B., 2001. Erosive wear behavior of various polyamides, Wear 249 (8), p. 702.
[12] Ruff, A.W., Ives, L.K., 1975. Measurement of solid particle velocity in erosive wear, Wear 35, p. 195.
[13] Wang, Y.Q., Huang, L.P., Liu, W.L., Li, J., 1998. The blast erosion behaviour of ultrahigh molecula weight polyethylene, Wear 218, p.
128.
[14] Sapate, S. G., Rama Rao, A. V., 2002. Effect of material hardness on erosive wear behavior of some weld-deposited alloys. J. Mate &
Mfg Proc. 17(2), p. 187-198.
[15] Tsiang, T.H., 1989. Sand erosion of fibre composites: Testing and evaluation. In Test Methods for Design Allowable for Fibrous
Composites, Chamis, C.C., Ed.; ASTM: Philadelphia, PA,2, p. 55.
[16] Pool, K.V., Dharan, C.K.H.; Finnie, I., 1986. Erosive wear of composite materials, Wear 107 (1), p. 196.
[17] Karasek, K.R., Goretta, K.C., Helberg, D.A., Routbort, J.L., 1992. Erosion in bismaleimide polymers and bismaleimide polymer
composites, J. Mater. Sci. Lett. 11, p. 1143.
[18] Hager, A., Friedrich, K., Dzenis, Y.A., Paipetis, S.A., 1995. Study of erosion wear of advanced polymer composites, In Proceeding of
ICCM 10, Street, K., Whistler, B.C., Eds., Woodhead Publishing., Cambridge,155.
[19] McLaury, B.S., Wang, J., Shirazi, S.A., Shadley, J.R., Rybicki, E.F, 1997. Solid particle erosion in long radius elbows and straight pipes.
Society of Petroleum Engineers, Paper No. SPE 388, pp. 42.
[20] Jayamathya, M., Seshana, S., Kailasa, S.V., Kumara, K., Srivatsanb, T.S., 2005. Influence of reinforcement and processing on the wear
response of two magnesium alloys, Journal of Materials and Manufacturing Processes, 20 (2), p. 255.
[21] Basavarajappa, S., 2009. Tool wear in turning of graphitic hybrid metal matrix composites, Journal of Materials and Manufacturing
Processes 24 (4), p. 484.
[22] Mohan, N., Natarajan, S., Kumaresh Babu, S.P., 2011. Sliding wear behaviour of graphite filled glass-epoxy composites at elevated
temperatures, Journal of Polymer-Plastics Technology and Engineering 50 (3), p. 251.
702 N. Mohan et al. / Procedia Engineering 68 (2013) 694 – 702

[23] Friedrich, K., 1986. Erosive wear of polymer surfaces by steel blasting, J. Material Sci. 21, p. 3317.
[24] Kuo-Jung Lee, Chun-Hung Wu, Huy –Zu Cheng, Chia-Chen Kuo, Han-Cheng, Tseng, Wen-Kai Liao, Shih-Fong Wei, Sheng-Feng Huang,
2012. Carbonization Rate and Impregnating Methods on the Tribological Behavior of Carbon/Carbon Composites, Procedia Engineering
36, p. 341.
[25] Arun Rout, Alok satapathy, 2013. Analysis of dry sliding wear behaviour of rice husk filled epoxy composites using design of experiments
and ANN, Procedia Engineering 38, p.1218.
[26] Arun Rout, Alok satapathy, Sisir Mantry, Ashok Sahoo, Tanmay Mohant, 2012. Erosion wear performance analysis of Polyester-GF-
Granite hybrid composites using the taguchi method, Procedia Engineering 38, p.1863.
[27] Jianbing Chen, Qiang Guo, Sigang Zhang, Xiaoming Wang, Xianli Shao, 2011. Research on Friction and Wear Behaviors of
PEEK/PEI/PES Plastics Alloys under Sliding Contact Condition, Procedia Engineering 36, p.285.
[28] Lingaraju, D., Ramji, K., Mohan Rao, N.B.R., Rajya lakshmi, U., 2011. Characterization and prediction of some engineering properties of
polymer - Clay/Silica hybrid nanocomposites through ANN and regression models, Procedia Engineering 10, p.9.