Development of Al-Cu-Fe Quasicrystal-Poly( p -phenylene sulfide) Composites
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Development of Al-Cu-Fe Quasicrystal-Poly(p-phenylene sulfide) Composites Paul D. Bloom, K.G. Baikerikar1, James W. Anderegg1 and Valerie V. Sheares Department of Chemistry, Iowa State University Ames, IA 50011, U.S.A. 1 Ames Laboratory, Iowa State University Ames, IA 50011, U.S.A ABSTRACT Quasicrystalline Al-Cu-Fe powders were used as a novel filler material in poly(p-phenylene sulfide) (PPS). These polymer/quasicrystal composites showed useful properties that may be beneficially exploited in applications such as dry bearings and composite gears. Al-Cu-Fe quasicrystalline filler significantly improved wear resistance to volume loss in polymer-based composites. In addition to improving the composite wear resistance, the Al-Cu-Fe filler showed low abrasion to the 52100 chrome steel counterface. Furthermore, mechanical testing results showed a two-fold increase in the storage modulus of the reinforced composites compared with the polymer samples. In addition, the Al-Cu-Fe filler was compared to its constituent metals, aluminum oxide, and silicon carbide in PPS. Chemical analysis of the wear interface by X-ray spectroscopy indicated the generation of a third body oxide layer during wear. The fabrication in addition to the thermal, mechanical, and wear properties of these unique materials is described.
INTRODUCTION Fillers and additives play an important role in the production of polymeric materials. The term filler is a generic label used for solid materials added to plastics. Fillers are often incorporated into plastics in large volumes. Plastics additives encompass other materials usually used in lower concentrations than fillers such as plasticizers, flame retardants, lubricants, and biocides. Both fillers and additives improve certain aspects of the end polymeric product. Historically, fillers are used to reduce the cost of plastics by replacing the more expensive resin with inexpensive materials such as calcium carbonate, kaolin clays, silicas, and talc. However, other value-added properties are gained through the use of fillers. Fillers can improve the physical, rheological, chemical resistance, thermal, optical, and electrical properties of a polymeric material. For example, talc can be defined as a reinforcing filler. In addition to reducing cost, talc-filled plastics have higher stiffness and better creep resistance than plastics containing other inexpensive fillers like calcium carbonate. Metallic fillers are used to increase the electrical and thermal conductivity of plastic materials. Metal-filled plastics have more specific uses such as anti-fouling compounds, corrosion-resistant paints, maintenance and repair products such as “cold-poured steel” and tooling [1]. New filler materials are continuously being investigated with the premise of combining the properties of the filler and the processibility, adhesive properties, and high strength to weight ratios of the polymer matrix. Quasicrystals, first discovered in 1984 [2], are complex metal alloys that are most comparable to ceramic particulate fillers in
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