Load- and time-dependent three-body abrasive wear in short carbon fiber- and cenosphere-reinforced polymer composites using machine learning approach

Abstract

This study investigates the load and time-dependent three-body abrasive wear behavior and surface morphology of polymer composites reinforced with varying proportions of short carbon fiber (Cr) and cenosphere (C) inclusions. Composites with different Cr and C reinforcements—Cr0C0, Cr0C20, Cr20C0, Cr15C5, Cr10C10 and Cr5C15—were subjected to wear tests under loads of 20, 30, and 40 N over exposure times of 5, 10, and 15 min. Mass loss and specific wear rate were evaluated to understand the influence of reinforcement composition and test parameters on wear performance. Surface morphological studies using scanning electron microscopy (SEM) revealed distinct wear mechanisms across composites. The Cr10C10 and Cr15C5 composites demonstrated the lowest specific wear rates of 9.42 × 10–9 and 8.67 × 10–9 m3/Nm, respectively, under a 40 N load at 10 and 15 min, correlating with smoother worn surfaces and fewer micro-cracks. In contrast, the Cr0C20 composite displayed the highest specific wear rate (5.14 × 10–8 m3/Nm) at a 40 N load for 5 min, with SEM images showing more extensive matrix erosion and cenosphere pull-out. The inclusion of cenospheres at higher ratios increased mass loss, especially in high-load conditions, while balanced Cr–C reinforcements (e.g., Cr15C5 and Cr10C10) provided enhanced abrasion resistance and minimized surface damage. These findings underscore the potential for optimizing Cr and C inclusion ratios to develop wear-resistant polymer composites suitable for demanding structural applications. © Iran Polymer and Petrochemical Institute 2025.