Enhancing High-Density Polyethylene with Yellow Oil Fly Ash: Mechanical, Physical, and Tribological Behavior Analysis
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Fly ash-reinforced polymer composites, known for their advantageous properties and environmental sustainability, have gained popularity. Heavy fuel oil fly ash, particularly yellow oil fly ash (YOFA), could serve as an enforcement component due to its mechanical properties. This study aims to introduce YOFA, a novel type of heavy fuel oil fly ash, as a potential reinforcement in high-density polyethylene (HDPE). The HDPE/YOFA composites were prepared using the injection molding technique after the extrusion blending process. The effect of YOFA content and particle size on mechanical and physical properties was investigated. The results revealed that the hardness slightly declined when the YOFA content and particle size were increased compared with the net HDPE. In contrast, the experimental density showed a positive correlation with the YOFA content and a negative correlation with the YOFA particle size. Additionally, the void content, water absorption, and thickness swelling increased gradually with YOFA content and particle size. A dry sliding wear test was conducted using the pin-on-disc method, and the following factors were chosen as independent variables: YOFA content, particle size of YOFA, applied load, and sliding time during the wear test. This method significantly affects two responses: wear loss and wear rate. Under steady-state conditions, wear resistance decreases with YOFA particle size and normal applied load. It also decreases with YOFA content up to 2 wt.%, followed by a gradual improvement up to 8 wt.%. On the other hand, with increasing sliding time, wear loss considerably increases while the wear rate significantly improves. The wear test conditions have been optimized using a full factorial design and Taguchi approach. A total of 320 experimental runs, each with one replication, have been conducted. The ANOVA analysis confirmed the robustness of the designed experiment, revealing that the factors contributing significantly, in order of importance, were sliding time, applied load, particle size of YOFA, and YOFA content. To minimize wear loss, the ideal settings were 8 wt.% YOFA content, the smallest particle size, an applied load of 5 N, and a sliding time of 5 minutes. Conversely, for optimizing the wear rate, the parameters were identical except for ......
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