Statistical modeling of multi-asperity wear and transfer in polymer-metal interfaces

Existing first-principle-based models have primarily addressed single-asperity interactions; however, the behavior of multiple contacting asperities remains inadequately understood. This study investigates the adhesive wear behavior and material transfer mechanisms of a multi-asperity interface in dry friction conditions , focusing on an alumina/polytetrafluoroethylene (PTFE) composite. By applying Rabinowicz's critical size criterion and Monte Carlo simulations, we analyzed the statistical wear characteristics of asperities. Our findings indicate that the simulated wear coefficient approximates 10 −4 , aligning well with experimental values. Additionally, the asperity size, material property, and their distribution strongly affect polymer wear behavior and material flow during the steady-state wear period. This research offers novel insights into the complex interactions at dry friction interfaces, paving the way for optimized material design and performance. • Simulated multi-asperity adhesive wear using the Monte Carlo method. • Polymer-metal transfer film growth stabilizes during steady wear. • Debris size and material properties distribution dictate wear rate dynamics. • Critical asperity size affects transfer film formation probability. • The model accurately predicts the wear coefficient compared to experiments.