Ultralow wear fluoropolymer composites: Nanoscale functionality from microscale fillers

Abstract Polytetrafluoroethylene (PTFE) filled with certain alumina additives has wear rates over four orders of magnitude lower than unfilled PTFE. The mechanisms for this wear reduction have remained a mystery. In this work, we use a combination of techniques to show that porous, nanostructured alumina microfillers (not nanofillers) are critical for this wear reduction. The microscale alumina particles break during sliding into nanoscale fragments. X-ray microtomography, transmission electron microscopy and infrared spectroscopy reveal nanoscale alumina fragments accumulated in the tribofilms. Tribochemically generated carboxylate endgroups bond to metal species in the transfer film and to alumina fragments in the surface of the polymer composite. These mechanically reinforced tribofilms create robust sliding surfaces and lead to a dramatic reduction in wear.