Tribological performance and microstructural insights of epoxy-based GFRP nanocomposites reinforced with ceramic nanoclays for wear-resistant applications

This study investigates epoxy-based glass fiber-reinforced polymer (GFRP) composites reinforced with hybrid ceramic nanoclays, platelet ‘PGV’ and tubular halloysite nanotubes (‘HNT’), for superior wear resistance. Ceramic nanoclays were combined in varying ratios (total 2 phr) to enhance slurry abrasion resistance. The optimized ‘7P1T’ composition (7 parts ‘PGV’, 1 part ‘HNT’) exhibited the lowest mass loss (576.68 mg) under severe conditions (14.96 kg load, 286.22 μm particles, 34,774.98 ppm slurry). The platelet ceramic nanoclay formed barrier layers, restricting abrasive particle penetration and enhancing fiber-matrix adhesion. In contrast, the ‘HNT’-dominated ‘1P7T’ sample showed the highest mass loss (1296.68 mg) due to poor interfacial bonding and weak crack resistance. SEM and TEM analysis confirmed intercalated ceramic nanoclay networks in ‘7P1T’, promoting crack deflection and stress redistribution, while ‘HNT’-rich samples exhibited fiber pull-out and poor filler dispersion. A regression model using response surface methodology (RSM) accurately predicted mass loss trends, with load identified as the most critical factor. This ceramic nanoclay hybrid approach offers a promising route to develop wear-resistant, self-lubricating composites for sustainable use in pumps, automotive, and tribological applications.