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Tribological Characterization of a Novel Ceramic-Epoxy-Kevlar Composite
Yassin Fouad1, Abdulrahman A Aleid1, Omer Osman1
1Department of Mechanical Engineering, King Fahd University of Petroleum and Minerals, Dhahran 31261, Saudi Arabia.
Polymers
|March 28, 2024
Summary
This study investigates the tribological behavior of a novel ceramic-epoxy composite. Increasing side load increases wear, but 115 rpm shows the lowest wear rate due to lubrication changes.
Area of Science:
- Materials Science
- Tribology
- Mechanical Engineering
Background:
- Drilling operations involve significant friction and wear between drillpipe tool joints (DP-TJ) and casing.
- Novel composite materials are being developed to enhance the durability and performance of downhole drilling components.
- Understanding tribological behavior under simulated downhole conditions is crucial for material selection and component design.
Purpose of the Study:
- To evaluate the tribological performance of a ceramic-epoxy composite lining under varying side loads and rotational speeds.
- To determine the effect of these parameters on wear depth, volume, and specific casing wear rate (K).
- To analyze the wear mechanisms and surface characteristics of the composite material.
Main Methods:
- Experimental tribological testing of a novel ceramic-epoxy composite in a Kevlar matrix casing against a composite-coated DP-TJ.
- Varying rotational speeds (65, 115, 154 rpm) and side loads (500, 700, 1000 N) under water-based mud (WBM) lubrication.
- Analysis of wear using digital microscopy, scanning electron microscopy (SEM), and energy-dispersive spectroscopy (EDS).
Main Results:
- Wear depth and specific casing wear rate (K) increased with increasing side load.
- The lowest specific casing wear rate (K) was observed at 115 rpm, attributed to a shift from boundary to hydrodynamic lubrication.
- Wear mechanisms transitioned from abrasive wear at lower speeds to adhesive wear at higher speeds, with side load having no significant effect on the mechanism.
Conclusions:
- The novel ceramic-epoxy composite exhibits varying tribological behavior influenced by rotational speed and side load.
- Optimizing rotational speed, specifically around 115 rpm, can minimize wear in this composite system.
- The material's wear resistance and mechanisms are dependent on operating conditions, suggesting tailored application strategies.
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