Wear Behavior of Aviation‐Grade Epoxy Nanocomposites Reinforced With Functionalized Graphene Nanoplatelets

ABSTRACT This study investigates the wear behavior of aviation‐grade epoxy nanocomposites reinforced with surfactant‐functionalized graphene nanoplatelets (s‐GNPs). Nanocomposites containing 0.5, 1, and 1.5 wt% s‐GNPs were synthesized via sonication and magnetic stirring, ensuring homogeneous dispersion. Wear tests under 20–40 N loads revealed that 1.5 wt% s‐GNPs improved the wear coefficient by 145% compared to neat epoxy, while reducing weight loss by 400%, 330%, and 380% at 20, 30, and 40 N loads, respectively, over a 1000 m sliding distance. Thermal imaging showed a more uniform heat distribution in s‐GNP composites, with temperatures stabilizing at 22.4°C (vs. 21.7°C for neat epoxy under 40 N). SEM/EDS analysis confirmed enhanced carbon covalent bonding and reduced oxidation, with 1.5 wt% s‐GNPs exhibiting 50% lower surface deformation than neat epoxy. Profilometry data demonstrated shallow, regular wear tracks (depth < 5 μm) for 1.5 wt% s‐GNPs, versus irregular grooves (> 10 μm) in neat samples. The optimal formulation (1.5 wt% s‐GNPs) achieved a wear rate of 4.8 × 10 ⁻⁶ g/m, 12× lower than neat epoxy (14.4 × 10 ⁻⁶ g/m at 40 N). These results highlight s‐GNPs' role in enhancing wear resistance through interfacial strengthening, tribofilm formation, and thermal conductivity, offering significant potential for aerospace applications.