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<p>Polymer gears are increasingly applied in precision transmission systems due to their low weight, corrosion resistance, and acoustic advantages, although their limited wear resistance continues to restrict long-term durability. To address this limitation, this study investigates epoxy-based composite gears reinforced with metal powders and modified with solid lubricants, aiming to enhance load-bearing and sliding wear performance. Epoxy composites are prepared by incorporating copper, iron, or aluminum powders as mechanical reinforcements and introducing polytetrafluoroethylene (PTFE), molybdenum disulfide, tungsten disulfide, or graphite as solid lubricants to improve lubricity. Ball-on-disc tribological tests under a 2 N normal load and a sliding speed of 0.1&#xa0;m/s indicate that PTFE-modified composites exhibit the lowest steady-state friction coefficients, reaching 0.203, 0.276, and 0.352 for copper-, iron-, and aluminum-filled systems. Wear track measurements further show substantial reductions in wear depth and width, with PTFE-modified composites demonstrating improvements of 73.93% and 45.54%. For example, the specific wear rate of aluminum composites decreases from 26.42 × 10⁻4 to 3.75 × 10⁻4 mm<sup>3</sup>/Nm. Microscopic examinations reveal a transition from severe abrasive features, including cracks and debris-induced ploughing, to milder abrasion characterized by finer grooves, suggesting that solid lubricants promote more stable sliding interfaces. All lubricant-containing composites also show reduced surface temperature during operation, with the aluminum–PTFE composite exhibiting a 20.01% decrease. These findings confirm that suitable combinations of metal powders and solid lubricants improve frictional stability, mitigate wear severity, and enhance the durability potential of epoxy-based composite gears for engineering applications.</p>

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Transformation of wear mechanisms and resistance improvement in epoxy based composite gears with solid lubricants

  • 期刊论文

  • 发表日期：

    2026年5月2日

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  • Chil-Chyuan Kuo,
  • Ding-Yang Li,
  • Zi-Huan Wang,
  • Yi-Xiang Ren,
  • Armaan Farooqui,
  • Song-Hua Huang,
  • Shih-Feng Tseng

摘要

Polymer gears are increasingly applied in precision transmission systems due to their low weight, corrosion resistance, and acoustic advantages, although their limited wear resistance continues to restrict long-term durability. To address this limitation, this study investigates epoxy-based composite gears reinforced with metal powders and modified with solid lubricants, aiming to enhance load-bearing and sliding wear performance. Epoxy composites are prepared by incorporating copper, iron, or aluminum powders as mechanical reinforcements and introducing polytetrafluoroethylene (PTFE), molybdenum disulfide, tungsten disulfide, or graphite as solid lubricants to improve lubricity. Ball-on-disc tribological tests under a 2 N normal load and a sliding speed of 0.1 m/s indicate that PTFE-modified composites exhibit the lowest steady-state friction coefficients, reaching 0.203, 0.276, and 0.352 for copper-, iron-, and aluminum-filled systems. Wear track measurements further show substantial reductions in wear depth and width, with PTFE-modified composites demonstrating improvements of 73.93% and 45.54%. For example, the specific wear rate of aluminum composites decreases from 26.42 × 10⁻4 to 3.75 × 10⁻4 mm3/Nm. Microscopic examinations reveal a transition from severe abrasive features, including cracks and debris-induced ploughing, to milder abrasion characterized by finer grooves, suggesting that solid lubricants promote more stable sliding interfaces. All lubricant-containing composites also show reduced surface temperature during operation, with the aluminum–PTFE composite exhibiting a 20.01% decrease. These findings confirm that suitable combinations of metal powders and solid lubricants improve frictional stability, mitigate wear severity, and enhance the durability potential of epoxy-based composite gears for engineering applications.