Influence of processing conditions on microstructural, mechanical and tribological properties of graphene nanoplatelet reinforced UHMWPE

Ultra-high molecular weight polyethylene (UHMWPE) is a relevant thermoplastic in industry and a well-proven standard biomaterial in joint replacements. To enhance its tribological properties while preserving its bulk ones, composite coatings on a UHMWPE substrate were prepared using non-functionalised graphene nanoplatelet (GNP) at reinforcement concentration of 0.1–5 wt% and two mechanical mixing techniques (ball mill or blade mixer) with different consolidation temperatures of 175–240 °C. Changes in morphology and size of the UHMWPE particles before hot-pressing were observed in function of the mechanical mixing techniques applied. Wear rate was affected by graphene content, reaching a minimum at 0.5 wt% GNP, with a reduction of 20 and 15%, for ball milling and blade mixer, respectively. However, blade mixer increased the wear rate by around twice respect the ball milling results, for all the studied materials. The coefficient of friction decreased notably, by ~25%, below 3 wt% GNP content, and hardness increased by 24%, regardless of the mechanical mixing process used. Finally, consolidation temperature had a positive influence on wear rate at temperatures of around 195 °C, which could be related to the free radical scavenger effect of the GNP. [Display omitted] •GNP/UHMWPE coatings were prepared by diverse mixing and temperature conditions.•Consolidation temperature around 195 °C improves the wear rate at low GNP content.•Mixing methods and GNP content provide an increase in hardness by 24% respect to PE.•GNP introduces a minimum in COF with both techniques with reductions by around 30%.•Mixing and GNP content influenced the wear rate, providing a minimum at 0.5 wt%.