Wear‐Activated Surface Engineering of Thermoplastic Polyurethane/Graphene Nanoplatelet Nanocomposites for Ice Friction Control

ABSTRACT Graphene‐reinforced thermoplastic polyurethane (TPU) composites offer a promising route for developing multifunctional polymer composites with improved mechanical durability, wear resistance, and surface‐dependent frictional performance. In this study, TPU nanocomposites reinforced with pristine and acid‐functionalized graphene nanoplatelets (GNPs and f /GNPs) were developed to investigate how reinforcing particle chemistry, filler loading, interfacial adhesion, and surface morphology influence composite performance. GNPs and f /GNPs were incorporated into TPU at 20 and 40 parts per hundred rubbers (phr) by solution mixing, followed by morphological, mechanical, thermal, abrasion, and ice‐friction characterization. Acid functionalization introduced polar surface groups on the GNPs, promoting improved filler dispersion and stronger interfacial interactions with the TPU matrix. These microstructural and interfacial improvements enhanced stress transfer, increased tensile stiffness, improved thermal stability, and reduced abrasion volume loss at optimized filler loading. In parallel, wire‐brushed surface textures were introduced to evaluate the role of controlled surface morphology in frictional response under ice‐sliding conditions. Textured and post‐abrasion surfaces showed that asperities and microchannels generated at the composite surface contributed to friction retention by increasing mechanical engagement with the ice interface and facilitating liquid removal during sliding. Among the investigated formulations, TPU‐20 f /GNP provided the most balanced performance, combining the lowest abrasion volume loss with sustained post‐abrasion ice traction. In contrast, excessive f /GNP loading restricted matrix deformability and promoted brittle wear. These findings establish an interface‐driven and surface‐evolution‐based design strategy for graphene‐reinforced TPU composites requiring coupled wear durability and frictional performance.