Development of high performance poly (ether-ketone) composites based on novel processing technique

• Probe sonication was explored as an aid to homogenous mixing of solid lubricants in matrix.
• Probe sonication proved useful in improving tribological properties, but not mechanical properties.
• SEM and EDAX were used to reveal the difference in wear mechanism.

Homogeneous mixing of ingredients by efficient method is necessary for desired performance of a composite. In this work, selected solid lubricants and powder of poly ether ketone (PEK) were mixed by probe-sonication method and then composites were developed incorporating short fibers during extrusion process followed by injection molding. Another batch of composites was developed by conventional mechanical powder mixing method instead of sonication. The developed composites were evaluated for physical, thermo-physical, mechanical and tribological properties (in two types of wear modes viz. adhesive and abrasive). The influence of mixing technique on all performance properties was extensively studied including SEM and EDAX studies on the surfaces of worn composites. It was concluded that the probe-sonication technique proved beneficial for improving tribological properties significantly, but not for all mechanical properties. The extent of influence depended on type of solid lubricants, fibers and operating parameters during tribo-evaluation.

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