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Review Article | Open Access

A review on tribology of polymer composite coatings

Yilong REN1, Lin ZHANG1, Guoxin XIE1(), Zhanbo LI1, Hao CHEN1, Hanjun GONG1, Wenhu XU2, Dan GUO1, Jianbin LUO1()
State Key Laboratory of Tribology, Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China
School of Mechatronics Engineering, Key Laboratory of Tribology, Nanchang University, Nanchang, Jiangxi 33003, China
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Abstract

Self-lubricating polymer composite coatings, with tailorable tribological and mechanical properties, have been widely employed on mechanical parts to reduce friction and wear, which saves energy and improves the overall performance for applications such as aerospace satellite parts, shafts, gears, and bushings. The addition of functional fillers can overcome the limitations of single-polymer coatings and extend the service life of the coatings by providing a combination of low friction, high wear resistance, high load bearing, high temperature resistance, and high adhesion. This paper compares the heat resistance, and the tribological and mechanical properties of common polymer matrices, as well as the categories of functional fillers that improve the coating performance. Applicable scopes, process parameters, advantages, and limitations of the preparation methods of polymer coatings are discussed in detail. The tribological properties of the composite coatings with different matrices and fillers are compared, and the lubrication mechanisms are analyzed. Fillers reduce friction by promoting the formation of transfer films or liquid shear films. Improvement of the mechanical properties of the composite coatings with fillers of different morphologies is described in terms of strengthening and toughening mechanisms, including a stress transfer mechanism, shear yielding, crack bridging, and interfacial debonding. The test and enhancement methods for the adhesion properties between the coating and substrate are discussed. The coating adhesion can be enhanced through mechanical treatment, chemical treatment, and energy treatment of the substrate. Finally, we propose the design strategies for high-performance polymer composite coating systems adapted to specific operating conditions, and the limitations of current polymer composite coating research are identified.

Keywords

polymer coatingstribological propertiesmechanical propertiesadhesion propertiescoating design

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Friction
Volume 9 Issue 3,
June 2021
Pages 429-470
DOI: 10.1007/s40544-020-0446-4
Cite this article:
REN Y, ZHANG L, XIE G, et al. A review on tribology of polymer composite coatings. Friction, 2021, 9(3): 429-470. https://doi.org/10.1007/s40544-020-0446-4
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10.1007/s40544-020-0446-4.T001Properties of common polymer matrices.

Materials T g/Tm/Ts (℃)Mechanical propertiesChemical resistanceCOF
Tensile strength (MPa)Young’s modulus (GPa)
EP50-80/*/120 [7]52.98 [8]3.15 [8]Good0.6-0.7 [9,10]
PF240 [11]/*/260 [12]53.2 [13]7 [13]Good0.42 [14]
ATSP240 [15]/*/260 [16]88 [17]4.35 [17]Good0.22 [16]
PU-42/168 [18]/85 [19]24.8 [20]57.8 [20]Fair0.34 [21]
PI212 [22]/375/221 [23]101 [24]1.9 [24]Good0.49 [25]
PTFE125/327 [26]/260 [19]33 [27]0.27 [27]Good0.07-0.1 [28,29]
PA6675/263 [30]/140 [31]80 [32]2.41 [32]Only alkali0.44 [33]
PA659/224 [34]/120 [31]68 [35]3.4 [35]Only alkali0.41 [36]
PAI277 [37]/*/260 [38]138 [39]4.1 [39]Only alkali0.2 [40]
PEEK143/340 [41]/260 [42]90 [43]3.0 [43]Good0.3-0.4 [44,45]
UHMWPE-133 [46]/135 [47]/90 [19]32.8 [48]0.6 [48]Good0.10-0.16 [49,50]
PPS85 [51]/286 [52]/220 [53]78 [54]2.5 [54]Good0.45 [55]
POM-60/170 [56]/120 [57]55.5 [58]2.65 [58]Poor0.3-0.33 [59,60]

Note: * means the polymer has no melting temperature.

10.1007/s40544-020-0446-4.T002Comparison of polymer coating preparation methods.

MethodsSubstrateFeedstockFactors affecting coating qualityStrengths and weaknesses
Brush/ roller coatingAny substrateSolutionSubstrates surface quality Manual skill✓ Better wetting, suitable for small area, less waste and pollution✗ Low efficiency, uneven coating thickness, and poor repeatability
Dip coatingAny substrateSolutionViscosity, density, surface tension, concentration, immersion time, extraction speed, number of cycles, substrate properties✓ Simple, scalable, fast, low cost, suitable for large-scale preparation of uniform coatings✗ Poor adhesion
Spin coatingAny substrateSolutionMolecular weight, concentration, viscosity, solvent evaporation rate, solvent diffusivity, volatility, rotational angular velocity✓ Short preparation time, uniform thickness and low equipment cost✗ Substrate size limited by equipment and only suitable for flat substrates
Air sprayAny substrateSolutionSolution viscosity, spray gun pressure, spray distance and angle✓ Suitable for large area substrate, uniform coating✗ High equipment requirements and low coating deposition efficiency
Electro-static sprayAny substrateSolution PowderSpray voltage and current, the rest is the same as air spray✓ Uniform coating, strong adhesion, high coating deposition efficiency and high coverage✗ Paints need good conductivity, expensive equipment, high voltage danger
Thermal sprayNon-polymerPowderSpray particle temperature, particle speed, spray angle and distance, particle size, filling method, substrate temperature, surface quality, roughness, substrate cooling rate✓ The paint is powder, no volatile pollution, eliminating the need for expensive solvent treatment, not limited by the melt viscosity and thermal conductivity of the substrate, high deposition efficiency✗ Noisy, not suitable for polymer substrates, problems such as oxidation, evaporation, degumming, residual stress, gas release of materials are inevitable
Cold sprayAny substratePowderParticle speed (greater than critical speed), others are the same as thermal spraying✓ Suitable for a variety of substrates, avoiding the disadvantages of thermal spraying, and good coating adhesion✗ Large equipment, unstable process and low powder utilization rate
Hot press sinteringNon-polymerPowderSintering temperature, pressure, time✓ Simple and low equipment cost✗ Not suitable for large area coatings

10.1007/s40544-020-0446-4.T003Friction properties of typical polymer composite coatings.

MatrixFillerSubstrateMethodsThicknessSteady state friction coefficientEar rate/life
EpoxyKH550-Fullerene [74]Cast ironBrush250 μm0.68 (0 wt%)-0.6 (0.5 wt%) (3 N，0.01 m/s) 316L steel0.006 (0 wt%)-0.002 (0.5 wt%) mm2
KH550-fullerene [74]Cast ironBrush250 μm0.68 (0 wt%)-0.6 (0.5 wt%) (3 N，0.01 m/s) 316L steel0.006 (0 wt%)-0.003 (0.5 wt%) mm2
Graphene (G) [154]Gcr15 steelSpray30 μm0.60 (0 wt%)-0.11 (4 wt%) (4 N, 0.072 m/s) Gcr15 steel6.54 (0 wt%)-1.0 (4 wt%) ×10-6 mm3/(N·m)
Carbon nanotubes / zinc sulfide [77]SteelSpray—0.76 (0 wt%)-0.42 (1.25 wt%) (1.5 N, 200 rpm) Gcr 15steel19 (0 wt%)-1 (1.25 wt%) ×10-4 mm3/(N·m)
Graphite (GP) [157]Tinplate——0.56 (0 wt%)-0.32 (50 wt%) (25 N, 0.84 m/s) 45 steel27 (0 wt%)-18 (50 wt%) ×10-11 mm3/(N·m)
Tung oil @ polysulfone capsules (TO@PUF) [92]Steel—200 μm0.46 (0 wt%)-0.35 (10 wt%) (1.0 MPa, 0.51 m/s) stainless steel38.64 (0 wt%)-13.10 (10 wt%)×10-14 m3/(N·m)
Tung oil @ polyureal capsules (TO@PUF) [93]Steel—300 μm0.46 (0 wt%)-0.38 (10 wt%) (1.0 MPa, 0.51 m/s) stainless steel38.64 (0 wt%)-8.26 (10 wt%)×10-14 m3/(N·m)
70SN Lubricant @ PS/SiO2 cpsule (O@PS/SiO2) [95]Aluminum——0.57 (0 wt%)-0.27(10 wt%) (1.0 MPa, 0.51 m/s) steel3.86 (0 wt%)-0.273 (10 wt%) ×10-13m3/(N·m)
Oily diatomite [158]SteelElectrostatic spray250 ±10 μm0.59 (0 wt%)-0.095 (16 wt%) (2.0 MPa, 0.76 m/s) steel0.088 (0 wt%)-0.0014 (16 wt%) g/h
Phenolic resin30 wt% polyfluo-wax graphite [159]45 steelSpray60-70 μm0.179 (0 wt%)-0.201 (30 wt%G) (320 N, 2.56 m/s); 0.187 (320 N) -0.1 (720 N) (10 wt%, 2.56 m/s); 0.24 (1.28 m/s)-0.14 (3.84 m/s) (10 wt%, 320 N)675 (0 wt%)-1,700 (10 wt%); 1,700 (320 N)-200 (720 N); 1,700 (2.56 m/s)-450 (3.84 m/s) m/μm
30 wt% polyfluo-wax MoS2 [159]45 steelSpray60-70 μm0.179 (0 wt%)-0.202 (40 wt%G) (320 N, 2.56 m/s); 0.182 (320 N)-0.12 (720 N) (10 wt%, 2.56 m/s); 0.22 (1.28 m/s)-0.16 (3.84 m/s) (10 wt%, 320 N)675 (0 wt%)-300 (50 wt%); 450 (320 N)-150 (720 N); 450 (2.56 m/s)-150 (3.84 m/s) m/μm
20 wt% polyfluo-wax graphene [160]45 steelSpray—0.179 (0 wt%)-0.125 (0.3 wt%) (320 N, 2.24 m/s); 0.125 (320 N)-0.100(620 N) (0.3 wt%, 2.24 m/s); 0.14 (2.24 m/s)-0.13 (3.68 m/s) (0.3 wt%, 320 N) steel400 (0 wt%)-4,000 (0.3 wt%);4,000 (320 N)-600 (620 N); 4,000 (2.24 m/s)-2,000 (3.68 m/s) m/μm
Polyphenylene sulfideCarbon fiber [55]45 steelFlame spray250-350 μm0.45 (0 wt%)-0.4 (5 wt%) (200 N, 0.43 m/s) stainless steel8 (0 wt%)-19 (5 wt%) ×10-6mm3/(N·m)
30 wt% polyfluo-wax Graphene [6]45 steelSpray50 μm—(100 N, 0.43m/s) GCr steel5 (0 wt%)-50(5 wt%)m/μm
PTFE [133]SteelSpray40-50 μm0.36 (0 vol%)-0.18 (40 vol%) (320 N, 1.25 m/s); 0.18-0.15 (320-700 N)0.2-0.15 (0.75-2.5 m/s) steel230 (40 vol%);230-25; 240-60 m/μm
PHBAPA66 MoS2 [161]45 steelBrush20-40 μm0.043 (150 (Kpa·m)/s)-0.033 (1,800 (Kpa·m)/s)（20 wt% PA66, 30 wt% MoS2）steel2×10-6 mm3/(N·m)
Polyurethane30 wt% polyfluo-wax TDI-carbon nanotubes [156]45 steelSpray50-60 μm0.171 (0 wt%)-0.225 (3 wt%) (320 N, 2.56 m/s); 0.20 (320 N)-0.13 (520 N) (1 wt%, 2.56 m/s); 0.202 (1.28 m/s)-0.185 (3 m/s) (10 wt%,320 N) steel700 (0 wt%0-1,800 (3 wt%); 1,500 (320 N)-900 (620 N); 500 (0.64 m/s)-1,800 (3 m/s); m/μm
30 wt% polyfluo-wax silica [91]SteelSpray30-40 μm0.17 (0 wt%)-0.14 (1 wt%) (320 N, 2.56 m/s); 0.16 (320 N)-0.07 (820 N) (3 wt%, 2.56 m/s); 0.20 (0.64 m/s)-0.16 (3.84 m/s) (3 wt%, 320 N) steel300 (0 wt%)-750 (3 wt%); 750 (320 N)-500 (820 N); 500 (0.64 m/s)-1,000 (3.84 m/s); m/μm
30 wt% polyfluo-wax HDI-titanium dioxide nanotubes (TiNT) [155]SteelSpray30-50 μm0.135 (320 N)-0.05 (1,620 N) (1 wt%, 2.56 m/s); 0.20 (1.28 m/s)-0.13 (3.84 m/s) (1 wt%, 320 N) steel2,750 (320 N)-1,000 (1,620 N); 2,750 (2.56 m/s)-2,500 (3.84 m/s); m/μm
20 wt% polyfluo-wax ionic liquid @ SiO2 capsule [94]SteelSpray40-50 μm0.20 (0 wt%)-0.09 (20 wt%) (3 N, 2.5 cm/s); 0.09 (3 N)-0.05 (10 N) (20 wt%, 2.5 cm/s) GCr15 steel500 (0 wt%)-200 ( wt%); 170 (3 N) -550 (10 N); μm
30 wt% polyfluo-wax silicon carbide [70]45 steelSpray40-50 μm0.172 (0 wt%)-0.133 (5 wt%) (320 N, 2.56 m/s); 0.13 (320 N)-0.06 (820 N) (5 wt%, 2.56 m/s); 0.23 (0.64 m/s)-0.14 (3.84 m/s) (5 wt%, 320 N) steel300 (0 wt%)-600 (5 wt%); 600 (320 N) -500 (820 N); 200 (0.64 m/s) -800 (2.0 m/s); m/μm
30 wt% polyfluo-wax zirconia (GrO) [70]45 steelSpray40-50 μm0.172 (0 wt%)-0.137(1 wt%) (320 N, 2.56 m/s); 0.15 (320 N)-0.05 (820 N) (5 wt%, 2.56 m/s); 0.23(0.64 m/s)-0.12 (3.84 m/s) (5 wt%, 320 N) steel300 (0 wt%)-1,000 (5 wt%); 1,500 (420 N)-450 (820 N); 4,00 (0.64 m/s) -1,000 (2.56 m/s); m/μm
PTFE [21]BabbittSpray8-10 μm0.34 (0 wt%)-0.15 (7 wt%)(3.08 MPa,0.08 m/s) GCr15 steel2.03 (0 wt%)-1.35 (3 wt%) ×10-4 mm3/(N·m)
PolyimideMoS2@HCNT [5]SteelSolution cast50 μm0.4 (0 wt%)-0.35 (2.0 wt%) (20 N, 12 cm/s) GCcr15steel1.5 (0 wt%)-0.75 (0.5 wt%) ×10-6 mm3/(N·m)
Fluorinated graphene (FG) [162]SteelSolution cast100 μm0.39 (0 wt%)-0.36 (0.25 wt%) steel1.5 (0 wt%)-0.8( 0.5 wt%) ×10-5 mm3/(N·m)
PTFE silicon nitride [132]45 steelSpray—0.346 (pure), 0.149 (20 PTFE), 0.140 (20 PTFE, 5Si3N4) (4 N, 0.33 m/s); 0.140-0.123 (4-10N, 0.33 m/s); 0.117-0.130 (0.11-0.77 m/s, 8 N) Gcr15 steel2.736, 1.313, 0.244; 0.244-0.1; 0.65-0.55; ×10-4 mm3/(N·m)
L-phenylalanine -graphene (LG) [25]SteelSolution cast50 μm0.49 (0 wt%)-0.44 (0.6 wt%) (3 N, 2 Hz) steel3.9-0.82×10-5 mm3/(N·m)
Fullerene (C60) [163]SteelSolution cast150-200 μm0.25 (10 N, 1 m/s) steel15-1×10-7 mm3/(N·m)
Boron nitride(BN), silicon nitride, perfluoropolyether(PFPE), platelets(Lapis) [164]SteelSpray29 μm0.06 (2 N, 10 mm/s) steel>1,000 cycles
PolyamideimideOligomeric silsesquioxane (POSS)-MoS2 [137]SteelSpray25 μm0.09 (50 wt% MoS2); 0.085 (5 wt% OPSS); 0.08 (5 wt% OMPOSS) (10 N, 100 mm/s)7; 3;2×10-6 mm3/(N·m)
Oligomeric silsesquioxane (POSS)-PTFE [134]SteelSpray25-30 μm0.073 (0 wt%)-0.057 (7 wt%) (5 N, 0.1 m/s) steel6.5 (0 wt%)-3.4 (7 wt%) ×10-6 mm3/(N·m)
PolyamideGraphene [138]45 steelFlame spray250-350 μm0.33 (0 wt%)-0.15 (1 wt%) (200 N, 0.43 m/s); steel6.5 (0 wt%)-3.5 (5 wt%) ×10-4 mm6/(N·m)
MoS2 [138]45 steelFlame spray250-350 μm0.33 (0 wt%)-0.23 (7 wt%) (200 N, 0.43 m/s) steel20 (0 wt%)-10 (1 wt%) ×10-6 mm3/(N·m)
Alumina [138]45 steelFlame spray250-350 μm0.33 (0 wt%)-0.23 (10 wt%) (100 N, 0.43 m/s) steel6.5 (0 wt%)-3.5 (0.5 wt%) ×10-4 mm3/(N·m)
PolyetheretherketoneSilicon carbide [44]AluminumBrush40 μm0.31-0.20 (0 wt%, 1 N, 0.2-1.4 m/s); 0.29-0.36 (0 wt%, 9 N, 0.2-1.1 m/s); 0.36-0.42 (7 wt%, 1 N, 0.2-0.8 m/s); 0.35-0.25 (7 wt%, 9 N, 0.2-1.4 m/s) steel20-75 (0 wt%,); 25-150 (0 wt%); 10-25 (7 wt%); 30-60 (7 wt%)×10-6 mm3/N·m
Silica [165]SteelElectrostatic spray150 μm0.35 (0 vol%)0-0.37 (15 vol%) (3N, 0.13 m/s); 0.37-0.46 (3 N-11 N, 0.13 m/s) steel27-21; 21-40 ×10-6 mm3/(N·m)
Non-polar fullerene tungsten disulfide [45]SteelSpray30 μm0.4 (0 wt%)-0.15 (2.5 wt%) (1 N, 30 mm/s) steel—
ATSPPTFE [135]Cast ironSpray20-25 μm0.077 (5 wt%, 445 N, 3.6 m/s)8.50×10-7 mm3/(N·m)
Graphene [136]SteelElectrostatic spray30 μm0.215-0.1 (25-300 ℃, 4 MPa, 1 m/s, 5 wt%); steel1.75-0.5×10-5 mm3/(N·m)
PTFE [136]SteelElectrostatic spray30 μm0.22 (25 ℃)-0.098 (180 ℃)-0.11 (300 ℃) (4 MPa, 1 m/s,7.5 wt%); steel0.25-0.5×10-7 mm3/(N·m)
UHMWPESingle wall carbon nanotube [166]SteelDip coating55 μm0.08-0.16 (0-0.2 wt%) (4 N, 1,000 rpm) steel6; 15; >25; >25×104 cycles
Graphene [167]AluminumElectrostatic spray90 μm0.33-0.30 (0 wt%-2 wt%) (2 MPa, 0.1 m/s); 0.32-0.20 (2-8 MPa, 0.1 m/s, 1 wt%); 0.27-0.14 (0.1-1.0 m/s, 4 MPa, 1 wt%) steel37-18.2 (1.0 wt%); 18.2-56.1 (6 MPa); 40.6-50.9 μm/km
C15A Organoclay [49]AluminumElectrostatic spray125 μm0.16 (0 wt%); 0.18 (0.5 wt%); 0.17 (1.5 wt%)；0.15 (3 wt%)(9 N, 0.1 m/s) steel5,000; 6,000; > 10,000; 8,500 cycles
Carbon nanotube [50]AluminumDip coating55 μm0.1 (0 wt%)-0.016 (0.1 wt%) (45 N, 0.57 m/s) steel25 (0 wt%)-200 (0.1 wt%)×104 cycles
PTFECarbon nanotube [129]SiliconSpin coating5 μm0.16-0.11 (1 wt%) (20 nN, 4 mm/s) steel5-2×10-4 mm3/(N·m)
Graphite [28]SteelDip coating8-1.2 μm0.074 (0 wt%)-0.061 (1 wt%) (0.5 N, 2.5 mm/s) steel0.7-4×104 cycles
Copper [168]SteelDip coating1.2 μm0.07 (0.5 N, 2.5 mm/s) steel20,000 cycles
Epoxy [130]Steel—100-150 μm0.2-0.13 (50 wt%) (3 N, 0.025 m/s) steel1×10-3 -3×10-6 mm3/(N·m)
Graphene oxide [127]Stainless steelSpin coating—0.15 (0 vol%)-0.05 (15 vol%) (5 N, 4 mm/s) 0.03 (15 vol%, 5 N, 4 mm/s,400 ℃) steel26 (0 vol%)-2 (15 vol%) (400 ℃) ×10-7 mm3/(N·m)
Gold [29]Stainless steelDip coating0.2-0.5 μm0.10 (0 wt%)-0.05 (0.06 wt%) (0.2 N, 2.5 mm/s); 0.09 (0 wt%)-0.07 ( wt%) (0.5 N, 2.5 mm/s) chrome steel307-608 cycles (0.2 N) 174-263 cycles (0.5 N)
Polyparaben [128]BronzeSpray15-20 μm0.108 (0 wt%)-0.139 (20 wt%) (0.5 N, 0.1256 m/s) Gcr15 steel13 (0 wt%)-3.9 (15 wt%) ×10-4 mm3/(N·m)

10.1007/s40544-020-0446-4.T004Suitability of different test methods for coating-substrate systems.

Thin coating (<20 μm)High coating (>20 μm)
D-BD-DB-BB-DD-BD-DB-BB-D
Interface indentation✓—✓✓————
Surface indentation————✓—✓✓
Cross-section indentation————✓—✓✓
Scratch (by load)✓—✓✓————
Scratch (by laser)————✓ ✓✓
Blister✓✓——✓✓✓—
Laser spallation✓✓——✓✓——

Note: D-B means coating-substrate systems. B means brittle and D means ductile.