Effect of Al2O3 and SiC Fillers on the Structure and Properties of UHMWPE-Based Composite Coatings Produced by Flame Spraying

This study investigated the structure and properties of flame-sprayed composite coatings based on ultra-high molecular weight polyethylene (UHMWPE) modified with Al2O3 and SiC ceramic fillers. The results of the composite coatings showed that the filler particles were preserved within the polymer matrix, covered by polymer fibers, and strongly bonded to the matrix. The X-ray diffraction analysis showed that for the samples containing Al2O3, the degree of crystallinity decreased from 77% to 64%, while for the SiC-containing samples, it remained in the range of 71–76%. The maximum microhardness was achieved in the coating with 15 wt.% Al2O3, reaching 8.15 ± 0.5 HV0.03, which represents a 50.9% increase compared with the initial UHMWPE coating. In the case of the SiC filler, the maximum microhardness was achieved at a content of 20 wt.%, reaching 7.40 ± 0.4 HV0.03. The abrasive wear test results demonstrated that both fillers enhanced the wear resistance of the coatings. The coatings containing 15–20 wt.% SiC exhibited the highest wear resistance, with a mass loss of approximately 0.02 g. In the case of the Al2O3 filler, the minimum mass loss was achieved at a content of 20 wt.%, reaching approximately 0.032 g.