In the diverse applications of plastic products, wear resistance serves as a critical performance indicator that significantly influences both the usability and lifespan of plastic components. As plastics are increasingly used in automotive, mechanical engineering, electronics, and other industries, enhancing their wear resistance has become more important than ever. To effectively reduce friction and wear, two primary methods are commonly used: adding lubricating substances and incorporating reinforcing materials. As a result, integrating reinforcing materials to improve wear resistance and self-lubrication has emerged as the preferred solution in the industry. Below, we explore seven commonly used fillers that enhance the wear resistance of plastics.
While lubricants can reduce friction to some extent, they come with notable drawbacks. Over time, oils can degrade, diminishing their lubricating effect. They also require regular maintenance and reapplication, which increases operational costs and labor. Moreover, lubricants tend to attract dust and debris, leading to contamination of internal parts and potential equipment failure.
1. Polytetrafluoroethylene (PTFE, Teflon)
Discovered by DuPont in 1938, PTFE is widely known as Teflon. It offers exceptional non-stick properties and outstanding self-lubrication, making it ideal for non-stick coatings such as those used in cookware.
As a wear-resistant additive, PTFE micropowder has the lowest coefficient of friction among all friction-reducing additives. It forms a smooth, lubricating film on part surfaces, reducing wear effectively—especially in high-load applications. The optimal addition ratio is 15% for amorphous plastics and 20% for crystalline plastics. PTFE micropowder is widely used in engineering plastics, coatings, inks, lubricants, and rubber to improve wear resistance, scratch resistance, and anti-stick properties while enhancing overall lubrication. For instance, PTFE-reinforced POM components demonstrate superior wear resistance and extended service life.
2. Molybdenum Disulfide
Molybdenum disulfide (MoS₂) is a dark solid lubricant powder with a metallic sheen and a smooth texture. It performs exceptionally well under high temperature and pressure, often regarded as a top-tier solid lubricant.
In engineering plastics, it is mainly used to reinforce nylon. For example, Nylon 66 blended with MoS₂ shows improved stiffness, hardness, and dimensional stability compared to pure resin. The crystal structure of MoS₂ enhances the material’s load-bearing capacity and wear resistance. Although impact strength may be slightly reduced, it is widely used in gears, bearings, seals, and sliders to reduce wear and enhance operational reliability.
3. Graphite
Graphite has a layered lattice structure that allows its molecules to slide easily under minimal friction. This property is especially valuable in wet environments where water can increase friction.
As a wear-resistant additive, graphite is often applied in components exposed to water, such as pump housings, impellers, and valve seals. It significantly boosts the wear resistance of plastics in moist or underwater conditions, reducing maintenance needs and extending service life.
4. Polysiloxane
Polysiloxane is a migratory wear-resistant additive. When added to thermoplastics, it gradually migrates to the surface and forms a continuous protective film.
The viscosity of polysiloxane determines its performance—lower viscosity leads to faster migration and better wear resistance. However, if too thin, it may evaporate or migrate too quickly, reducing its effectiveness. Selecting the right viscosity is essential for optimal performance.
5. Glass Fiber
Glass fiber is an inorganic material made mainly from silicon dioxide. It offers high strength, thermal resistance, and corrosion resistance.
Although brittle on its own, it significantly reinforces plastic structures by providing mechanical bonding between polymer molecules. This integration enhances structural integrity and wear resistance. It is commonly used in pumps, valves, bearings, gears, and supports to improve durability and load-bearing capacity.
6. Carbon Fiber
Carbon fiber is produced by carbonizing organic precursors at high temperatures. Like glass fiber, it improves structural integrity, wear resistance, and load capacity.
However, it is softer and less abrasive than glass fiber, making it suitable for applications where surface scratching must be avoided. Its self-lubricating properties make it ideal for oil-free bearings, gears, and piston rings in high-end applications such as aerospace and precision machinery.
7. Aramid Fiber (Kevlar)
Aramid fiber, developed by DuPont in the 1960s, is a high-strength synthetic fiber with excellent heat and chemical resistance. It is five to six times stronger than steel.
As a wear-resistant additive, it is softer and less abrasive than glass or carbon fibers. It is particularly useful in applications where surface protection is critical. For example, in combination with ultra-high molecular weight polyethylene, it is used in tactical helmets to improve wear resistance and impact absorption.
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