Leverage of cenosphere filler size on mechanical and dry sliding wear peculiarity of polyester composites

This investigation focuses on understanding the effects of submicron size cenosphere fillers on mechanical and wear properties of unsaturated polyester composites. The composites in this study are fabricated with 10 wt.% of 900 nm, 600 nm and 300 nm diameter cenosphere filler particulates. Neat unsaturated polyester composite is also prepared for comparative analysis. The sliding wear test is performed on a pin-on-disc tribometer with the composite pin sliding over a disc comprising hardened ground steel. Friction and wear tests are conducted over a range of sliding velocities (1.57–4.71 m/s), normal loads (10–40 N) and sliding distances (1000–4000 m). In this study, 300 nm size of cenosphere particulate-filled composite shows high wear resistance ability among all fabricated composites. Mechanical properties such as hardness, tensile strength, flexural strength and compressive strength are also investigated. It is observed that mechanical properties of the composites increase with decrease in the particle size. Composites reinforced with 300 nm size of cenosphere particulate shows superior mechanical properties when compared to the other composites in this study. Worn surface morphology of composite specimens has been examined by scanning electron microscopy to understand dominant wear mechanisms.