High Wear Resistance of Ultralow-Wear Polyethylene with Different Molecular Weights Under Different Contact Pressure

Ultralow-wear polyethylene (ULWPE), a type of polyethylene homocomposite with excellent wear resistance, has recently been reported; however, its underlying wear mechanism has yet to be clarified. In the current study, three different molecular weights of ULWPE from 205 to 748 kg/mol were experimentally evaluated on a multidirectional motion pin-on-disk wear tester under a contact pressure from 2 to 4 MPa, compared with conventional UHMWPE. The high wear resistance mechanism of ULWPE was investigated with respect to mechanical, microstructural, and surface properties. Compared with UHMWPE, ULWPE had excellent wear resistance. Structure and mechanical characterization showed that the crystallinity and lamellar thickness of ULWPE were significantly higher than those of UHMWPE, which endowed ULWPE with high hardness and strength. Despite its considerably smaller molecular weight than that of UHMWPE, ULWPE still had high interphase content, leading to its superior toughness. The crystallinity, lamellar thickness, Young’s modulus, yield stress, and elongation at break of ULWPE exhibited a downward trend with the increase of molecular weight. Conversely, the interphase content of ULWPE increased with the molecular weight increase. Among all the ULWPE samples, ULWPE with a molecular weight 748 kg/mol had the least wear, as a result of combined both excellent strength and adequate toughness. With an increase in contact pressure, the wear losses of different polymers tended to increase. The wear losses of the least wear ULWPE were 4.71 ± 0.04 mm³/Million Cycles (Mc), 5.11 ± 0.37 mm³/Mc, and 5.77 ± 0.62 mm³/Mc under 2, 3, and 4 MPa. Comprehensive strength and toughness reduced abrasive wear and adhesion wear, endowing ULWPE with excellent wear resistance.