Synergistic effect of carbon fillers on tribological behaviour of Kevlar fabric reinforced epoxy composites for high-performance contact applications

This study investigates the wear behaviour of Kevlar fiber-reinforced epoxy composites hybridized with carbon filler, focusing on their tribological properties under varying operational conditions. Composites were fabricated using 0.5, 2, and 4 % carbon filler by weight, and tested at sliding velocities of 1 m/s, 1.5 m/s, and 2 m/s under applied loads of 10 N, 20 N, and 30 N. Wear tests revealed that the wear rate increased with higher filler content and sliding speed, with wear values ranging from 8.12 to 24.38 microns. The coefficient of friction (COF) exhibited an increasing trend with higher filler content, peaking at 0.47 for composites with 4 % filler at 30 N load and 1.5 m/s sliding speed. Design of Experiment (DOE) results showed that 0.5 % carbon filler provided the most stable COF and wear resistance across all conditions and composites with 4 % filler exhibited higher wear. Machine learning prediction was carried out to evaluate the wear and coefficient of friction of carbon filled Kevlar fabric composites. Scanning Electron Microscopy (SEM) analysis revealed wear mechanisms including abrasion, adhesion, and material transfer. The findings highlight that moderate carbon filler concentrations enhance wear resistance and frictional performance, enabling their applications in automotive, aerospace, and other high-performance contact applications.