Tribological enhancement of seal blocks using petrochemical diesel carbonaceous particles

Abstract Polymeric sealing materials are essential in industrial systems; however, their tribological limitations under harsh conditions often lead to premature failure. This study presents a cost-effective approach to enhancing the friction and wear resistance of rubber-based sealing materials by incorporating petrochemical diesel carbonaceous particles (PDCP), a byproduct of diesel combustion. PDCP-modified seal blocks were synthesized through compounding and vulcanization, and their structural, chemical, and tribological properties were systematically analyzed. Characterization results revealed that PDCP exhibits a nanoscale, nearly spherical morphology with embedded graphite fragments and disordered carbon, along with oxygen-containing functionalized carbon domains on the surface. Friction tests demonstrated that the addition of PDCP reduced the average friction coefficient and significantly decreased wear under applied loads of 10 N and 30 N. Morphological analysis of the worn surfaces using scanning electron microscopy indicated that the enhanced performance was attributed to the rolling bearing effect of PDCP, which minimized direct contact between the sealing substrate and the counterpart steel. These findings underscore the dual role of PDCP as a friction-reducing and wear-resistant filler, offering a sustainable strategy for the development of high-performance sealing materials in industrial applications.