1. Experimental Investigation on Friction and Wear
Behaviour of Nano Clay Polymer Hybrid Composites
A.Thiagarajan1
, S.Bharanidharan2
, K.Shanmugatharasu3
, S.Surendhra Coumar4
, N.Suresh Raja5
, K.Velmurugan6
1
Associate Professor, 2, 3,4,5
Student, 6
Head of the department, Department of Mechanical Engineering
Sri Manakula Vinayagar Engineering College, Madagadipet, Puducherry-605107, India
1
thiagusmvec@gmail.com
2
bharanidharan28@gmail.com
Abstract— The objective of the present work is to analyse the effect
of Nano clay as filler and aluminium as an additional
reinforcement on wear behaviour of glass fibre reinforced epoxy
polymer composites. Epoxy resin is taken as matrix material and
the combination of woven roving mat and chopped strand mat
(glass fibres) and aluminium is taken as reinforcement. The
composite laminates were fabricated by varying weight percentage
of Nano clay using hand lay-up technique. The wear test was
conducted by Pin on disc method. The specific wear rate and
weight loss was calculated and it showed the influence of Nano clay
in the composites. Scanning Electron Microscope (SEM) was used
to analyse the morphological structure of the prepared laminates.
The SEM image showed the uniform distribution of the particles.
Hence
Keywords— Nano Clay; Hybrid Composites; Glass Fibres; Pin On
Disc; SEM
I. INTRODUCTION
Polymers and their composites are emerging as viable
alternative products to metal-based ones in many common and
advanced engineering applications [1]. A composite material
can be defined as a combination of two or more materials that
results in better properties than those of the individual
components used alone. In contrast to metallic alloys, each
material retains its separate chemical, physical, and mechanical
properties. The two constituents are reinforcement and a matrix.
The main advantages of composite materials are their high
strength and stiffness, combined with low density, when
compared with bulk materials, allowing for a weight reduction
in the finished part [2]. The reinforcing phase provides the
strength and stiffness. In most cases, the reinforcement is harder,
stronger, and stiffer than the matrix. The reinforcement is
usually a fibre or a particulate. Particulate composites have
dimensions that are approximately equal in all directions. They
may be spherical, platelets, or any other regular or irregular
geometry. Particulate composites tend to be much weaker and
less stiff than continuous fibre composites, but they are usually
much less expensive. Particulate reinforced composites usually
contain less reinforcement (up to 40 to 50 volume percent) due
to processing difficulties and brittleness. Many composites used
today are at the leading edge of materials technology, with
performance and costs appropriate to ultra demanding
applications such as spacecraft. But heterogeneous materials
combining the best aspects of dissimilar constituents have been
used by nature for millions of years. Ancient society, imitating
nature, used this approach as well: the Book of Exodus speaks
of using straw to reinforce mud in brickmaking, without which
the bricks would have almost no strength [3].
Wear occurs to the hardest of materials, including
diamond, wear studies having focused on surface damage in
terms of material-removal mechanisms, including
transfer film, plastic deformation, brittle fracture and
tribochemistry [4]. More recently, experiments and testing on
coated materials have occurred and some standardized, and
experimental test equipment has been produced to meet
specifications on wear resistance. Standard test methods such as
pin-on disc are used extensively to simulate rubbing action in
which plastic yielding occurs at the tip of individual
asperities. This testing is mainly carried out on a microscopic
scale and in thin films technology [5].
The present work is to make a composite material with
Nano Clay by varying weight percentage of 0%, 1%, 3% and
5% weight as a filler material with hybrid fibres and provide
better wear resistance for their applications.
II. EXPERIMENTAL PROCEDURE
A. Fabrication Process
Bisphenol-A based epoxy resin LY 556 with hardener
HY 951 both provided by Huntsman were used as the matrix
material. The glass fiber used was in the form of Chopped
Strand mat (CSM) and Woven roving mat (WRM). The
Aluminium of the grade Al6061T6 along with glass fiber were
used as reinforcement material. Organo modified clay called
montmorillonite (MMT) the alkyl ammonium based clay

2. commercially available in the trade name called Garamite-1958
bought from southern clay product USA was used as filler
material. In dispersion of Nano Clay into the epoxy resin is the
first step in the fabrication process. The Nano Clay was mixed
into the epoxy resin and the mixture is stirred for 2 hours at 800
rpm using high speed mechanical stirrer. Then curing agent is
used in stoichiometric ratio with respect to the epoxy resin. This
mixture which consists of Epoxy, Nano Clay and curing agent
had been applied over the CSM glass fiber which has been cut to
the size of (150mm*150mm). CSM and WRM each of two
layers and one layer of Aluminium had been used. The roller
was then applied onto the surface of mat to achieve uniform
distribution of mixture into the glass fiber, and also help to
remove the air bubbles. The laminate was allowed to cure for
24hrs. Post-curing was carried out at 120°C for 4 h and further
cooled to room temperature.
Fig. 1. Fabrication process
B. Test Procedure
Research conducted by Glaeser and Ruff reported
that pin-on-disc were the most widely used wear test
processes[6]. A pin-on-disc test setup was used for calculating
the slide wear of the samples. Specimen is prepared in the
cuboid shape of 30mm*5mm*5mm dimensions. Prior to testing,
the test samples were rubbed against a 600-grade SiC paper. The
setup was initially weighed using a digital electronic balance
(0.1 mg accuracy) and test was carried out by applying normal
load of 20N which is allowed to run for a constant sliding
distance 500 m and at a sliding velocity of 2m/s. A minimum of
three trials was conducted to ensure repeatability of test data
The difference in the weight of the sample is the measure of
wear loss. The coefficient of friction can be obtained by
dividing the frictional force by the applied normal force. At the
end, selected samples are examined by Scanning Electron
Microscope.
Fig. 2. Specimen Clamping on Holder
III. RESULTS AND DISCUSSION
A. Wear test by pin on disc method
The table 1 and 2 shows the calculated values of weight
loss and specific wear rates as below. From these values, the
weight loss at 3 % of filler material was excellent due to the
uniform dispersion of the filler particles. Weight loss has been
reduced to the maximum extent at 3% when compared to other
samples without any changes in the mechanical properties. The
specific wear rates of the composite materials were used for the
characterization of wear behavior of the composites.
TABLE 1. CALCULATION OF WEIGHT LOSS
Nano
Clay
Powder
(%)
Load
(N)
Speed
(rpm)
Timer/
Revolution
(min)
Initial
Weight
(gm)
Final
Weight
(gm)
Weight
Loss
(gm)
0 19.62 320 4.16 1.057 1.0552 0.0018
1 19.62 320 4.16 1.1425 1.1414 0.0011
3 19.62 320 4.16 1.2029 1.2026 0.0003
5 19.62 320 4.16 1.2746 1.2741 0.0005
TABLE 2. CALCULATION OF SPECIFIC WEAR RATE
Nano clay
powder (%)
Density
(Kg/m3
)
Change in
volume
(x 10-10
m3
)
Specific wear
rate (x 10-14
m3
/Nm)
0 1409.33 12.772 13.02
1 1523.33 7.221 7.36
3 1603.87 1.87 1.91
5 1699.47 2.942 2.99

3. Fig. 2. Effect of Nano clay powder on wear for 2kg load
The above figure shows that the wear behaviour of
composite material keeps on decreasing by increasing the
addition of Nano clay powder. Hence Nano clay powder can
be added as a filler material in order to reduce the wear rate.
But the limit of using Nano clay powder for reducing the wear
rate is up to 3% usage. For over usage i.e. 5% Nano clay usage
in the prepared laminate shows higher wear rate than 3%.
Fig. 3 SEM image of worn surfaces at 5% weight of Nano Clay
The above figure shows the worn surfaces at 5%
weight of Nano Clay which is viewed under Scanning Electron
Microscope. As the Nano Clay weight percentage was
increased to 5%, the fracture surface became rougher and
provides more wear to the composite materials.
IV. CONCLUSION
 The Nano composite hybrid laminates were
successfully prepared with 0,1,3 and 5 percentage
weight of Nano Clay.
 The prepared laminates were cut according to ASTM
G99 standard for wear.
 Wear test was conducted for the load of 2kg and it is
observed that the wear rate is less for 3% when
compared to 0%, 1% and 5%.
 The impact of aluminium in the laminate reduces the
wear rate than the laminate without aluminium.
 Better bonding and even distribution of Nano Clay
reduces the wear rate and hence the addition of Nano
Clay as filler material reduces the wear rate of material.
 The wear rate is higher in 5% Nano clay than 3% Nano
clay laminate is due to agglomeration and improper
distribution of Nano Clay.
 It is also clearly shows that addition of Nano clay
powder improved the interfacial properties between
the fibre and matrix, which results in good resistance of
wear rate.
ACKNOWLEDGMENT
We sincerely thank our Head of the department
Dr.K.Velmurugan whose continuous encouragement and
sufficient comments enabled us to complete our project
REFERENCES
[1] ASM Handbook, ASM International, Materials Park, USA, 18, 1992.
[2] F.C. Campbell, Introduction to Composite Materials, Structural
Composite Materials, ASM International, 2010.
[3] David Roylance, INTRODUCTION TO COMPOSITE
MATERIALS, 2000
[4] J.M. Martin, Th. le Mogne, Interpretation of friction and wear
of ceramics in terms of surface analysis, Surf. Coat. Tech. 49
(1991) 427–434.
[5] R. Blickensderfer, J.H. Tylczak, Laborabory tests of spalling,
breaking and abrasion of wear-resistant alloys used in mining
and mineral processing, Department of the Interior, Bureau of
Mines Report of Investigation, 1985.
[6] D.M. Kennedy and M.S.J. Hashmi, “Methods of wear testing for
advanced surface coatings and bulk materials”, Journal of Materials Processing
Technology 77, pp. 246–253, 1998.
[7] From Wikipedia (Online). Available at http://en.wikipedia.org.
0
50
100
0 25 50 75 100 125 150 175 200 225 250
WEARRATE(MICROMETER)
TIME (SECOND)
Time Vs Wear rate
Load - 20N, Velocity - 2m/s, Sliding
distance - 500m
Nano
clay 0%
Nano
clay 1%
Nano
clay 3%
Nano
clay 5%