Wear, 121 (1988) 127 - 141 127

THE EFFECT OF FIBER ORIENTATION ON THE ABRASIVE WEAR

BEHAVIOR OF POLYMER COMPOSITE MATERIALS

M. CIRINO
Center for Composite Materials, University of Delaware, Newark, DE (U.S.A.)

K. FRIEDRICH

Polymer and Composites Group, Technical University of Ham burg-Harburg, Ham burg
(F.R.G.)

R. B. PIPES

College of Engineering, University of Delaware, Newark, DE (U.S.A.)

(Received May X3,1987; accepted June 30,1987)

The effect of fiber orientation on the dry abrasive-dominant wear

behavior of continuous-carbon-fiber-reinforced polyetheretherketone (CF-
PK) and continuous-aramid-fiber-reinforced epoxy (K49/3501-6) was inves-
tigated. A pin-on-flat type test apparatus was employed in determining the
wear rates as a function of fiber orientation for the two materials. Different
wear rate distributions were found for each material, although the optimum
wear resistance occurred when the fibers were oriented normal to the sliding
surface in each case. The influence of fiber-abrasive particle interactions on
the wear rate distribution is discussed with regard to microscopic observa-
tions of the worn surfaces. Lastly, the wear rate distributions are described
empirically allowing the prediction of the wear rate at any arbitrary fiber
orientation.

1. Introduction

The wear behavior of composite materials is influenced by the orienta-

tion of the fibers relative to the sliding direction. The dependence of the
wear rate on the fiber orientation is difficult to model in a quantitative man-
ner. To increase further the complexity of the matter, the effect of the
fiber orientation on the wear rate also depends on the type of composite
material under consideration as well as on the type of tribological system
under which it operates. This anisotropic wear behavior has been investi-
gated for several types of composite materials such as polymer matrix and
metal matrix [ 1,2] composites, short fiber [ 3 - 61, continuous fiber [ 7 - lo]
and woven [ll] composites and even hybrid composites [12]. These studies

OQ43-1648/88/$3.50 0 Elsevier Sequoia/Printed in The Netherlands

128

evaluated wear rates for sliding either against smooth steel or under severe
abrasion.
This paper describes the ~vest~ation of the effect of fiber orientation
on the dry abrasive wear behavior of composite materials consisting of uni-
directional continuous fibers and polymer matrices. Wear rates as well as
microscopic wear mechanisms were studied for several fiber orientations.
A correlation of the microscopic observations of the wear mechanisms to
the wear rate dist~butions is attempted in a qualitative manner. Lastly,
empirical re~tionships of the wear data are used to predict the wear rate at
arbitrary fiber orientations.

2. Experimental details

Two unidirectional, continuous fiber polymer composite materials

were investigated in this study, namely, carbon-fiber-reinforced polyether-
etherketone (CF-PK) (material supplied in pre-impregnated tape form
(APCZ) by ICI Americas) and aramid-fiber-reinforced epoxy (AF-EP) (mate-
rial supplied in pre-~preg~~ tape form by the Fiberite Coloration).
Each material system was cured by the process procedures recommended by
the material suppliers. Table 1 describes these materials in more detail.

TABLE 1
Composite materials employed in the wear tests

Abbreviation Material Fiber Density

volume (g cm-3)
fraction

EP 3501-6 epoxy resin - 1.28

AF-EP K49 aramid fiber-epoxy 60% 1.34
PK Polyetheretherketone (PEEK) - 1.27
CF-PK AS4 carbon fiber-PEEK 55% 1.56

All feasible fiber orientations with respect to the sliding direction can
be described by two rotational parameters CYand 6. Figure 1 illustrates a
fiber located at an orientation defined as (a,@). The QIrotations are defined
as counterclockwise rotations about the Z-axis, and the j3 rotations are
defined as counterclockwise rotations about the 3-axis. At each position,
a local coordinate system can be introduced where the l-axis (also l’- and
l”-axis) coincides with the longitudinal axis of the fibers. This will allow
a t~~d~en~on~ description of the wear rates as a function of fiber
orientations relative to the sliding direction. To facilitate the achievement
of all possible fiber orientations, the (x rotations must range from -90” to
+90”, and the ~3rotations must range from 0 to 90”.
 129

Fig. 1. Illustration of the Q and p rotational parameters used for fiber orientation des-
cription.

Normal Parallel Antiparallel

lb I p)=w)l I(a ,p )=WO)l I(a . P)=wo)1

Fig. 2. The three basic fiber orientations (N, P and AP) for unidirectional continuous-
fiber-reinforced composite materials.

Owing to the nature of unidirectional composite materials, three basic

fiber orientations are easily identified with respect to the sliding surface as
depicted in Fig. 2. This terminology is commonly used in the tribobgical
study of composite materials. When the fibers are perpendicular to the
sliding surface plane the normal (N) orientation ((a$) = (0,O)) exists. This
orientation is further categorized as an out-of-plane orientation where the
plane refers to the sliding surface plane. In the same context, the other two
orientations are considered as m-plane orientations. More specifically, the
parallel (P) orientation ((o$) = (90,O)) exists when the fibers are in-plane
and parallel to the sliding direction, and the antiparallel (AP) orientation
((a$) = (0,90)) exists when the fibers are in-plane and perpendicular to the
sliding direction.
Fig. 3. Simplified illustration of the pin-on-flat test apparatus.

2.2. Test procedures

A pin-on-flat apparatus was employed which is illu~ra~d schematically
in Fig. 3. A more detailed description of the apparatus is given in ref. 13.
Specimens of cubic geometry were used for all tests whose apparent contact
area A was approximately 10 mm 2. A 220 grit non-waterproof type silicon
carbide (Sic) abrasive paper was used as the counterface material. A detailed
description of waterproof and non-waterproof type abrasive papers is given
in ref. 13. According to the man~act~er, the average Sic particle diameter
D was 70 flm.
The materials were tested in the three basic orientations (N, P and AP)
as shown in Fig. 2. Further tests were then done on fiber orientations be-
tween the N and P orientations, between the N and AP orientations, and
between the P and AP orientations. These intermediate orientations are
schematically illustrated in Fig. 4.
Generally, the specimens were moved in contact with the Sic paper at
a constant velocity v of 300 mm mm-’ and at an apparent pressure p of

t-OO”.O”, (.6O”P1 1.3W.O’) iO’,O”) (JO’,O’) (60’,0’1 (w-,0-1

cl 0 cl
Fig. 4. Illustration of the fibers on the wear surfaces for orientations between the N. P
and AP orientations.
 131

2.2 MPa for a sliding distance L of 500 mm. Four runs in the same direction
were made for each specimen. Each run was on a fresh track of Sic paper
(single-pass conditions). The mass loss of the specimen was observed after
each run on a Mettler analytical balance (0.1 mg) under the same environ-
mental conditions as the test was conducted. All tests were performed in
controlled laboratory air which was at about 22 “c and 35% relative humidity.
The wear behavior was characterized by defining a dimensionless wear
rate W which relates volume loss AV to sliding distance L and apparent
contact area A in the following manner:

The volume loss can be found by using the mass loss Am and density p mea-
surements in the following form:

AV=!!
P
Inserting eqn. (1) into eqn. (2) yields a dimensionless wear rate which is
defined by experimentally measured test parameters:
Am
W= - (3)
PLA
Dividing eqn. (3) by the apparent normal pressure p yields the specific wear
rate W, as

w, = w (4)
P
which is given the units of millimetres cubed per Newton per metre. This
equation describes the physical nature of the specific wear rate as a volume
loss of material by a given amount of energy input. Often, the wear resis-
tance of a material is referred to which is simply the inverse of the wear rate
(W-i or W,‘).
Microscopic observations of the tested specimens were made by scan-
ning electron microscopy (SEM). All sample surfaces which were micro-
scopically observed under the scanning electron microscope were coated
with a thin layer of gold following standard procedures for polymeric mate-
rials.

3. Results

3.1. Wear rate as a function of fiber orientation

The average dimensionless wear rate distribution of the CF-PK system
for various fiber orientations is illustrated graphically in Fig. 5. As the fibers
proceeded from the P to AP and the N to AP orientations a relatively mono-
tonic increase in the wear rate was observed. The wear rate distribution
132

Fig. 5. The averaged dimensionless wear rate distribution of the CF-PK composite mate-
rial for various fiber orientations.

Fig. 6. The averaged dimensionless wear rate distribution of the AF-EP composite mate-
rial for various fiber orientations.

behaved in a non-symmetric fashion about the N orientation where a local

maximum occurred at (30,O) and (-60,O). Furthermore, the absolute mini-
mum occurred at the N orientation for the CF-PK system.
The wear rate is a function of material type as well asfiber orientation,
as illustrated by the drastically different wear rate distribution of the AF-EP
system shown in Fig. 6. As the fiber orientation ranged from P to AP a rela-
tively monotonic decrease in the wear rate was observed. Unlike for the
CF-PK system, the distribution of the wear rates behaved in a symmetric
fashion about the N orientation. The absolute minimum occurred also at the
N orientation. Furthermore, the distribution was relatively flat about the N
orientation illustrating the fact that the wear rate does not significantly
increase as the fibers proceed from the out-of-plane orientations towards the
in-plane orientations until they are predominantly in the in-plane orientation.

3.2. Microscopy of wear mechanisms

Basic wear mechanisms for unidirectional, continuous fiber-reinforced
polymers in an abrasive tribological system have been identified and dis-
cussed in detail for the three basic fiber orientations (N, P and AP) by Cirino
et al. [lo]. These are illustrated schematically in Figs. 7 - 9. An SEM photo-
graph of the worn surface of a (90,30) CF-PK specimen is shown in Fig. 10.
The fracture path left by a passing abrasive particle can be seen along with
Damage
Zonef

n
Fig. 7. Schematic illustration of the basic microwear mechanisms occurring in the N
orientation: A, fiber slicing; B, fiber-matrix debonding; C, fiber cracking; D, fiber bending.
Fig. 8. Schematic illustration of the basic microwear mechanisms occurring in the P orien-
tation: A, interlaminar crack propagation; B, fiber cracking; C, fiber-matrix debonding;
D, fiber fracturing.

Fig. 9. Schematic illustration of the basic microwear mechanisms occurring in the AP

orientation: A, fiber fracturing; B, fiber-matrix debonding.

Fig. 10. SEM photograph of the worn surface of the CF-PK in the (90,30) orientation.
The scar (S) left by the passing abrasive particle induces damage such as fiber fracture
(F), fiber-matrix debonding (D) and matrix removal (M).

the damage it has caused, e.g. fiber fracture, fiber-matrix debonding and
matrix removal. The in-plane orientations are characteristic of relatively
larger cut fiber pieces, whereas the out-of-plane orientations show evidence
of fiber slicing which produced relatively smaller cut fiber pieces and cracks
perpendicular to the surface (Figs. 11 and 12).
The wear mechanisms which occurred in the AF-EP system are differ-
ent from those in the CF-PK system. The AF-EP system behaved in a rela-
tively ductile manner resulting in a relatively smoother surface appearance
(Figs. 13 - 15). The in-plane orientations consisted of a high degree of fiber
deformation and fibrillation as shown in Fig. 13. In this case, the fibers were
cut and subsequently fibrillated by the passing abrasive particle. These dam-
aged fibers have a tendency to remain attached to the surface and required
more abrasive particle interactions before they were removed. In the out-of-
plane orientations, the fiber ends show a large plastic deformation (Figs. 14
and 15). The ability of the aramid fiber to deform plastically is shown in
Fig. 11. SEM photograph of the worn surface of the CF-PK in the (-60,O) orientation:
S, fiber slicing.

Fig. 12. SEM photograph of the worn surface of the CF-PK in the (0,30) orientation.

Fig. 13. SEM photograph of the worn surface of the AF-EP in the (90,30) orientation
showing a high degree of fiber fibrillation.

Fig. 14. SEM photograph of the worn surface of the AF-EP in the (0,60) orientation
showing highly deformed fiber ends.

Fig. 16. The passing abrasive particles have deformed the fiber such that on
the tensile side of the fiber, a fiber fibrillation phenomenon has occurred,
while on the compressive side of the fiber, kink bands are present.

4. Discussion

4.1. Differences in wear rate as a function of fiber orientation

The CF-PK system was observed to exhibit higher wear rates for the
--cy fiber orientations than for the +o fiber orientations. Figures 17 and 18
illustrate schematically the basic fiber-abrasive particle interactions which
occurred in each case respectively. For +CXorientations, the passing abrasive
particles caused the fibers to experience compression and bending. For --(II
orientations, however, the fibers experienced tension and bending. The
tension resulted in the damaged fibers experiencing a pull-out phenomenon.
Furthermore, in this case the tip of the abrasive particle is able to indent the
Fig. 15. SEM photograph of the worn surface of the AF-EP in the (30,O) orientation
showing highly deformed fiber ends.
Fig. 16. SEM photograph of the worn surface of the AF-EP in the (90,30) orientation.
The bent aramid fiber consists of fiber fibrillation (F) and kink bands (K).

Si
Part

Ma&x Fi:ber Makx

Fibbr
h
c =-
At, q Aeos a cos a
Fig. 17. Schematic illustration of the interactions between a fiber and a Sic particle for
the +(Y fiber orientations. The fiber experiences bending and compression. An and A, are
components of the bending force A imposed on the fiber by the passing Sic particle.

Fig. 18. Schematic illustration of the interactions between a fiber and a Sic particle for
the --(Y fiber orientations. The fiber experiences bending, tension and direct particle
indentation at point D. The maximum fiber length at which direct particle indentation
occurs is shown as I,.

fiber directly, thus enhancing the cracking and fracturing of the fiber. These
factors are responsible for the relatively higher wear rates in the --(II orien-
tations.
More specifically, when the fibers were oriented in the +(Y direction,
the (30,O) orientation case showed a slightly higher wear rate than the
(60,O) orientation case. Figure 17 shows schematically that the force A
applied to the fiber by the passing abrasive particle can be split into two
components. The first component is directed parallel to the longitudinal
axis of the fiber (A,) which places the fiber in a state of compression. The
second component is directed perpendicular to the fiber (A,,) causing the
fiber to bend and its magnitude is given by
Ab =A COSQ (5)
136

For the (30,O) orientation

A,(30,0) = 0.87A (6)
and for the (60,O) orientation
A,(60,0) = 0.54 (7)
Therefore

-4,(30,0) > A,(60,0) (8)

Theoretically, greater fiber damage is therefore expected in the (30,O) orien-
tation case than in the (60,O) orientation case. The damaged fibers can then
be subsequently removed resulting in the relatively higher wear rate for the
(30,O) orientation case.
When the fibers were oriented in the --(Y direction, the (-60,O) orien-
tation showed a higher wear rate than the (-30,O) case. Assuming that the
Sic abrasive particle penetrates to a constant depth h for each case (i.e. h is
only dependent on the apparent contact pressure), it is shown schematically
in Fig. 18 that the length of the fiber (I,) between the point at which the Sic
particle contacts the fiber and the fiber end at the surface is given by
h
1, = - (9)
cos a
Hence, for the (-60,O) orientation
Z,(-60,O) = 2h (10)
and for the (-30,O) orientation
1,(-30,O) = 1.15h (11)
Therefore
1,(-60,O) > I,(-30,O) (12)
Thus, in theory, the passing abrasive particles can damage the fibers to a
greater extent in the (-60,O) orientation case than in the (-30,O) orienta-
tion case. The damaged fibers can then be subsequently removed resulting
in a higher wear rate for the (-60,O) orientation case.
The AF-EP system exhibited relatively lower wear rates when the
fibers were near the out-of-plane orientation. As in the N orientation case,
the abrasive particles can only deform the fiber ends without causing any
fiber fracture or debonding. When the fibers are in-plane, material removal
is increased owing to the ability of the abrasive particles to bend the fibers
and remove them from the surface. This is enhanced by the poor quality of
the aramid fiber/polymer matrix interface. These mechanisms are not signifi-
cantly effective until cy reaches values which are very close to that of the P
and AP orientation; otherwise, the fibers are too far out of the sliding sur-
face plane. Hence this is the reason for the flat area at the minimum about
the N orientation. Even though each material system exhibited different
 137

wear behavior, there does exist one point in common; the optimal wear resis-
tance was exhibited in the N orientation for each material system.

4.2. Empirical wear equation

Given the wear data which was ascertained for the various fiber orienta-
tions under consideration, an empirical relationship was determined for pre-
dicting the wear rate at any arbitrary fiber orientation. Since wear depends
strongly on the tribological system under which it operates, the predicted
wear rates are only valid for that tribological system. The idea for the devel-
opment of such a relationship was inspired from studying the work of Horn-
bogen [ 141, who suggested that wear rates of anisotropic materials can be
described, in principle, by a “wear tensor” if the wear rates in the basic
directions of the material are known.
For each material system, a linear Coons surface [15] was constructed
from the given data. The surfaces are represented by a bivariate vector-valued
function

Q(w) = (Qol(~,~),Q~(u,~),Qw(u,u)) (13)

where the components of vector Q are illustrated schematically in Fig. 19.
Initially, it is necessary to define the four boundary curves of the surface.
These planar curves can be represented by a single-parameter vector-valued
function which may be obtained by fixing either u or u of Q(u,u) equal to 0
and 1. The necessary data are shown in Fig. 20 as projected onto the o-0
plane. A third-order polynomial fit was performed on each boundary curve.

Fig. 19. Illustration of the Qcu, Qp and Qw component vectors of the bivariate surface
vector Q(u,u).

Two surface patches were generated for each material system; one sur-
face (Q+) for the +o quadrant, and one surface (Q-) for the --(Y quadrant.
For the CF-PK system, the surfaces for (o$,W) space are given as
Q,y+(~,u)=~; O<u<l,u=a/90,ar>O (14a)
Qp+(u,u)=u; O< u<l,u=p/90 (14b)
QW+(u,u) = CIuu3 + C2u3u + C3u3 + C4uu2 + C& + C6u3
+c7u2+csuu+cgu*+c10u+cllu+c1~ (14c)
where
138

[1 I”1
(-QQ,Qo) (-30,90) (30.90) (60,Q'J)
=(90,30) =(90,60) + =(90,60) =(90,30)
0 0 0 4 0 0 0
(-90,90) i: (90,90) (%QO) (90,90)5: (0,OO)

0 1
c-90,60)
J (90,60) (0,601 (QOt)60,

(-90,30) : (90,30)

1 w ) a[“1
” w I w v
(-90,O) (-6080) (-30,O) (o,o) (30,O) (60,O) (Qo,Q)
Fig. 20. Data obtained from wear tests (0) and redundant data (c).

Cl = +o.ooo81 C,=+O.O0136 (144

c, = -0.00044 C8 = -0.00022
C3 = -0.00076 Cg = -0.00309
C4 = -0.00168 Cl0= -0.00027
cs = +0.00152 C1, = +0.00132
c, = +0.00180 Cl2=+0.00053
and
Qa-(u,u) = u; 0 < u G 1, .u = CY/-90, (Y< 0
Q&,v) = u; 0 < u < 1, u = ~/QO
Qw-(u,u)=C,uv3 +C2u3v+ C3u3+ C4uv2+C5u2v+Cgu3
+c,v2 +c$4v+c,u2 +c,($I+c,,u+c~~ (15c)
where
c, = +o.ooo81 C,= +0.00136 Wd)
c2 = +0.00521 C8 =+0.00219
C3 = -0.00076 CCJ= +0.00497
C4 = -0.00168 Cl0= -0.00027
C, = -0.00655 Cl1= -0.00109
c,= -0.00386 cl*= +0.00053
Similarly, for the AF-EP system, the surfaces for (cw,&W) space are given as
Q,+(u,v)=u; O<uGl,u=a/QO,a~O (16a)
Qp+(u,u) = u; 0 < v G 1, u = p/90 (16b)
QW+(u,v) = C,uv3 + C2u3u + C3v3 + C4uu2 + Csu2v + C,u3
+ c,u* + csuv + cgu2 + Cl,V + CllU + Cl2 (16~)
where
 139

C, = -0.000 46 Cl = -0.00100 (1W

c2 = -0.00370 cs = -0.000 09
cs = + 0.00138 cg = -0.002 29
Cd = -0.000 40 Cl,, = +O.OOO26
c5 = + 0.003 97 C,, = +O.OOO64
c6 = +0.002 35 cr* = +o.ooo 08
and
Qa-(u,u)
= u; 0 < u < 1, u = o/-90, CY
< 0 (174
Qp-(UJ) = u; 0 < u < 1, v = p/90 (17b)
Qw-(u,u) = C,uu3 + C2u3u+ C3u3 + C4uu2 + C,u2u + C6u3
+ c,u2 + csuu + cgu2 + c,ou + CllU + C,? (17c)
where
C, = -0.000 46 C7 = -0.00100 (17d)
c2 = -0.002 45 Cs = +o.ooo 30
c, = +0.00133 Cg = -0.000 64
c4 = -0.000 40 Cl0 = +O.OOO26
c, = +0.002 31 C11 = +O.OOO24
C, = +O.OOl 10 Cl2 = +o.ooo 08

With the above equations, surfaces were generated for the CF-PK and AF-EP
systems which are graphically displayed in Figs. 21 and 22 respectively.
Now, the dry abrasive wear behavior of the CF-PK and AF-EP systems
at any arbitrary fiber orientation can be predicted. The fiber orientation rela-
tive to the sliding direction can be described in terms of 01and fl as discussed
earlier. Next, the parameters u and u can be determined by the appropriate
relationships given above. The predicted value of the wear rate at the given
(Yand /3 can now be determined by evaluating the appropriate Qw (u,u) equa-
tion (eqns. (14c), (15c), (16~) and (17~)).

I 10-4
I
I
I
I
I
I
I
I I
~--,------__-~-f_________( ,

Fig. 21. Graphic display of the constructed surface using the empirical relationships
obtained from the wear data (Fig. 5) of the CF-PK composite material.
140

Fig. 22. Graphic display of the constructed surface using the empirical relationships
obtained from the wear data (Fig. 6) of the AF-EP composite material.

5. Conclusions
The abrasive wear rates of CF-PK and AF-EP were shown to depend
on the fiber orientation. Other factors, such as sliding direction and material
type, were also shown to influence the wear behavior of these materials as
portrayed by their drastically different wear rate distributions. The wear
rates of the CF-PK were strongly influenced by the direction of sliding rela-
tive to the fibers as well as by the fiber orientation relative to the sliding
surface. The effect of the sliding direction on the wear rate was qualitatively
described in a discussion of the fiber-abrasive particle interactions on a
microscopic level. An important influential factor is whether the abrasive par-
ticle compresses the fiber or tends to pull the fiber out as it passes. These two
mechanisms generate different levels of material removal where the latter
mechanism will tend to generate a higher wear rate. The wear rates of the
AF-EP exhibited a minimum when the fibers were oriented normal to the
sliding surface. In fact, the wear rate did not significantly change for fiber
orientation variations of up to about 30” about the normal orientation.
Observations of the microwear mechanisms show that material removal is
usually larger for the cases when the fibers are oriented in the plane of the
sliding surface and smaller when the fibers are oriented out of the sliding
surface plane. In general, the wear rate distributions followed these tenden-
cies. Furthermore, the dominating wear mechanisms in CF-PK were of the
microcracking and microcutting type, whereas in AF-EP, the dominating
wear mechanisms were of the microploughing type. The microploughing
mechanism was shown to generate a relatively smaller amount of material
removal which is reflected in a lower wear rate. This is especially evident
for AF-EP with fiber orientations between the normal and parallel orienta-
tions. Lastly, empirical relationships were determined for the two materials
allowing for the prediction of the wear rate at any arbitrary fiber orientation.

Acknowledgments
This project was funded by the National Science Foundation at the
University of Delaware through the Center for Composite Materials. The
 141

extensive SEM was done in coordination with the Polymer and Composites
Group at the Technical University of Hamburg-Harburg, F.R.G., through the
Deutsche Forschungsgemeinschaft under DFG project FRI-675-1-2.

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