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Studies show that the long-term operation of a rubber mixer results in wear at the end face of the mixer. End face wear increases the gap between the mixing chamber and the end face, resulting in leakage and a reduction in the mixing performance, affecting the final product's quality. Therefore, it is essential to investigate the wear of the metal face during the mixing process. The present study added aramid fibers to a rubber compound using a mechanical blender to obtain a composite material. Then, the influence of the aramid fibers on the metal friction and wear of the end face of the mixer was analyzed. This article introduces the concept of the wear ratio and explores the friction and wear of metals from the perspective of formulation technology for the first time. With the addition of aramid fibers, the proportion of abrasive wear of rubber on metal decreased, and the proportion of corrosive wear increased during the mixing process; however, when the addition of aramid fibers exceeded 3 phr, the balance of abrasive wear of rubber on metal increased and the proportion of corrosive wear decreased. It was found that aramid fibers have the property of friction reduction, which reduces the wear of the rubber blend on the metal. When the amount of aramid fibers added was 3 phr, the amount of abrasion of the rubber compound on the metal was the lowest. [ABSTRACT FROM AUTHOR]

The continuous operation of essential refining equipment, internal mixers, leads to wear on their end faces, resulting in an increased gap between the mixer chamber and the end face. This, in turn, causes material leakage, reducing mixing efficiency and adversely impacting rubber performance. Therefore, investigating metal wear on the mixer's end face during the mixing process is essential. Scholars have introduced dynamic covalent bonds into rubber molecular chains, bestowing self-repairing capabilities upon the materials. This innovation has significant implications for extending rubber lifespan and lowering production costs. It involves adding methacrylic acid (MAA) and excess zinc oxide (ZnO) to construct an ionic crosslinking network, limiting covalent crosslinking of rubber molecules and enabling in-situ polymerization of MAA/ZnO, resulting in self-repairing properties. However, it is crucial to consider corrosive wear induced by MAA's strong acidity on metals. This study combines MAA, ZnO, and multi-walled carbon nanotubes (MWCNTs) through mechanical mixing to create a composite material called zinc methacrylate (ZDMA)/MWCNTs/rubber. The research investigates the in-situ synthesis mechanism of MAA and ZnO and the synergistic mechanism of ZDMA and MWCNTs. The study analyzes the impact of MWCNTs additive amount on the frictional wear of the internal mixer's metal end face. During the mixing process, ZDMA is grafted and polymerized onto rubber's macromolecular chains, forming ionic pairs with strong electrostatic interactions, creating a primarily reversible supramolecular network dominated by ion crosslinking. This ion crosslinking network, along with the three-dimensional mesh structure of MWCNTs, establishes a stable spatial structure within the rubber matrix. The study reveals that increasing the MWCNTs content to 3 phr reduces the aggregation of SiO 2 particles and ZDMA granules within the rubber matrix, resulting in reduced friction coefficients, roughness, and wear rates of the metal. However, exceeding 3 phr of MAA content leads to excessive MWCNT aggregation within the rubber matrix, increasing wear rates, roughness, and friction coefficients due to hindrance of rubber macromolecular chain crosslinking and reduced SiO 2 particle dispersion within the rubber matrix. These findings provide valuable insights into the dynamics of frictional wear in internal mixers. • Continuous mixer use erodes end faces, widens gaps, and hampers rubber performance. • Adding dynamic covalent bonds to rubber enhances self-repair, extending lifespan and cutting production costs. • MAA, ZnO, and MWCNTs create ZDMA/MWCNTs/rubber, studied for frictional wear impact. • Elevated MWCNTs levels (up to 3 phr) lower wear rates, roughness, and friction in rubber. • Excessive MAA (> 3 phr) increases wear, roughness, and friction by blocking crosslinking and reducing dispersion. [ABSTRACT FROM AUTHOR]

Internal mixer is an important mixing equipment. After working for a long time, the end face of the internal mixer will be worn. The abrasion of the end face can increase the gap between the mixing chamber and the end face, and then material leakage occurs, which reduces the mixing effect and affects the performance of rubber compound. Therefore, it is very necessary to study the wear of the end face in the mixing process. As one‐dimensional nanomaterial, carbon nanotubes (CNTs) have a perfect hexagonal structure and many unusual mechanical, electrical and chemical properties. In recent years, with the deepening of the research of CNTs and nanomaterial's, their broad application prospects have also been continuously revealed. This paper analyzes the influence of rubber compounds with different CNTs content on the friction and wear of the end face from the perspective of formulation, and the correlation between corrosive wear and abrasive wear is studied. In the present study, it is found that as CNTs increase, the proportion of abrasive wear increases, the proportion of corrosive wear decreases, and the amount of the metal wear decreases. With the increase of CNTs, the hindering effect of CNTs on SiO2 molecules is strengthened, the degree of silanization reaction is reduced, the output of high‐temperature water vapor is reduced, and the corrosive wear of the metal is reduced. The spatial structure of CNTs is a cylinder with hexagonal plane, and it has extremely high toughness and softness, so it has slight wear on the metal. On the one hand, CNTs hinder the movement of SiO2 molecules. On the other hand, because CNTs have the wrapping effect on SiO2 molecules, some silica aggregates have no direct contact with the metal, CNTs become the medium for silica aggregates to contact with the metal. Therefore, with the increase of CNTs, the proportion of abrasive wear gradually increases, but the total amount of the metal wear gradually decreases. [ABSTRACT FROM AUTHOR]

Internal mixer is one the most commonly used rubber‐mixing equipment, which has been applied for decades. This device can operate continuously for a long time. Accordingly, it is quite probable to have wear of the end face of the mixer. Studies show that the end face wear increases the gap between the mixing chamber and the end face, resulting in material leakage, reducing the mixing effect and ultimately affecting the properties of the compound. Therefore, it is of significant importance to study the friction and wear of the mixing compound to the metal in the mixing process. Considering the superior characteristics of graphene (GE), it is considered a revolutionary material and has been widely applied in numerous applications. In the present study, the influence of the mixing compound with different amounts of GE on the friction and wear of the metal end face was analyzed and the ratio of the corrosion wear to abrasive wear was calculated for the first time. It was found that as the amount of GE increases, the proportion of abrasive wear on the metal increases, the proportion of corrosive wear on the metal decreases, and the metal wear decreases first and then increases. Moreover, the lowest metal wear can be achieved when the amount of GE is 3 phr. [ABSTRACT FROM AUTHOR]

Internal mixers play a critical role as blending equipment in the rubber industry, operating for extended hours under high intensity. Investigating the wear patterns of internal mixers holds paramount importance in curbing dust leakage and prolonging their operational lifespan during the mixing process. Thermal cracked carbon black (CBp), an economically viable material derived from waste rubber, stands as a potential substitute for other carbon blacks in specific applications. This substitution aids in waste rubber recycling, thereby promoting ecological sustainability. This study centers on the amalgamation of CBp and graphene oxide (GO) in varying proportions, incorporated into the rubber matrix via mechanical blending. The objective is to produce composite materials, namely CBp/GO/NR, and comprehend the synergistic mechanisms between CBp and GO. Furthermore, the study analyzes the impacts of different CBp/GO ratios on metal friction and wear at the internal mixer's end faces. Scanning electron microscopy (SEM) observations divulge a collaborative behavior between GO and CBp particles within the rubber matrix, culminating in a spatial "honeycomb" network structure. On one hand, GO's two-dimensional planar network structure aids in CBp particle dispersion. Conversely, this planar network restricts the overflow of aromatic oils in CBp particles, influencing oil film formation on the rubber surface. Simultaneously, the planar network of GO creates a physical isolation layer between the rubber and the metal components. The inclusion of GO in the rubber matrix introduces notable alterations in CBp particle dispersion, friction coefficient, metal surface roughness, and metal wear. In summary, the optimum interaction between GO and CBp particles is achieved when the GO content in the composite material reaches 4 phr. This interaction leads to superior CBp particle dispersion and minimal metal wear in the composite material. • Produce CBp/GO/NR composites, understand CBp and GO synergy. • Analyze CBp/GO ratios on metal friction/wear at mixer faces. • SEM shows collaborative GO and CBp behavior, "honeycomb" structure. • Optimal GO-CBp interaction at 4 phr in composite material. [ABSTRACT FROM AUTHOR]

As the essential mixing equipment, long hours of work can cause wear and tear on the end face of the compactor. The wear of the end faces leads to an increase in the gap between the chamber and the end faces, which leads to leakage, reduces the mixing effect, and ultimately affects the rubber properties. Therefore, it is necessary to study the end face metal wear during the mixing process. Thermally cracked carbon black, as recycled material for scrap rubber, can be used as a substitute for other carbon blacks in some fields, vastly reducing the production cost and promoting the reuse of scrap rubber. In this paper, thermally cracked carbon black (CBp) was mixed with multi-walled carbon nanotubes (MWCNTs) and added rubber by mechanical blending to obtain CBp/MWCNTs composites. The synergistic mechanism of CBp and MWCNTs was investigated to analyze the effect of CBp/MWCNTs ratios on the frictional wear of metal on the end face of the compactor. The results showed that MWCNTs cooperated with CBp particles to form a three-dimensional "grape bunch" network structure. On the one hand, the three-dimensional "grape bunch" network structure can adsorb CBp particles to promote the dispersion of CBp particles. On the other hand, the three-dimensional "grape bunch" network structure can also hinder the overflow of aromatic oil and affect oil film formation. At the same time, the three-dimensional "grape bunch" network structure can also form a physical isolation layer between the rubber and the metal. This significantly influences the degree of CBp particle dispersion, friction coefficient, metal surface roughness, and metal wear. It seems that the synergistic effect between MWCNTs and CBp particles is maximized when the content of MWCNTs in CBp/MWCNTs composites is 4 phr, the area of CBp/MWCNTs three-dimensional mesh is maximized, the dispersion of CBp particles is the best, and the wear of CBp/MWCNTs composites on metal is the lowest. • As the essential mixing equipment, long hours of work can cause wear and tear on the end face of the compactor. • The effect of the synergistic effect of CBp and MWCNTs on the friction and wear of end-face metal was analyzed. • The results showed that MWCNTs cooperated with CBp particles to form a three-dimensional "grape bunch" network structure. [ABSTRACT FROM AUTHOR]

Internal mixer is an important mixing component in industrial applications. Studies show that when a mixer operates for a long time, wear may appear at the end face of the internal mixer. On the other hand, abrasion of the end face increases the gap between the mixing chamber and the end face. Then, leakage occurs, which reduces the mixing effect and affects the rubber performance. Therefore, it is of significant importance to study the wear of the end face during the mixing process. Graphene oxide (GO) and multi-walled carbon nanotubes (MWCNTs) have excellent electrical characteristics and thermal conductivity so that they have been widely used in various fields such as synthesized composite rubbers. GO and MWCNTs are mechanically blended into natural rubber to obtain GO/MWCNTs composite material. In the present study, the influence of the GO/MWCNTs ratio on the friction and wear of the end face of the internal mixer is analyzed. The obtained results show that MWCNTs and GO molecules interact to form a three-dimensional network structure, which has a greater impact on the degree of silica dispersion, silanization reaction, and metal wear. As the GO content increases, the average friction coefficient between rubber and metal, metal roughness, the proportion of abrasive wear, and the amount of metal wear gradually decrease. The lowest values can be achieved when the amount of added GO is set to 3 phr. When the GO in the mixture exceeds 3 phr, the friction coefficient between rubber and metal, and the metal roughness change, thereby affecting the proportion of abrasive wear and increasing the amount of metal wear in the mixing process. In this experiment, the amount of CNT that reduces GO aggregation is 6 phr. On the whole, when the ratio of GO/MWCNTs is 3/6, the synergistic effect of MWCNTs and GO molecules is maximized, the area of the three-dimensional network structure of GO/MWCNTs is the largest, the dispersibility of SiO 2 is the best, and the amount of wear of the composite material on the metal is the lowest. • In the present study, the influence of the GO/MWCNTs ratio on the friction and wear of the end face of the internal mixer is analyzed. • The obtained results show that MWCNTs and GO molecules interact to form a three-dimensional network structure. • It is concluded that the metal wear is minimized when the ratio of GO/MWCNTs in the GO/MWCNTs composite is set to 3/6. [ABSTRACT FROM AUTHOR]

The gap between the rotor and the mixer chamber wall is an important factor in determining filler dispersion in rubber compounds. The inner wall of a mixer will wear after working for a long time, which will cause poor filler dispersion and affect the quality of rubber products. In this study, MoDTC was added to carbon black as a kind of filler, and the effect on filler dispersion, the properties of the rubber product, and the friction and wear of rubber and metal in the mixing process were examined. Experimental data showed that after adding 3 phr of MoDTC, carbon black dispersion was greatly improved, the curing time was shortened, and the performance remained stable. It was also found that the Mo element of the compound with 3 phr MoDTC dispersed better than that of the other compounds. Most importantly, adding 3 phr of MoDTC greatly reduced the amount of wear on the metal during the mixing process. However, the opposite effect occurred when the MoDTC content was high. The method proposed in this study can not only improve filler dispersion in rubber but also reduce metal wear to prolong the service life of the mixing chamber when applied to an actual mixing process. [ABSTRACT FROM AUTHOR]

As the basic equipment in the rubber field, the internal mixer is suitable for long-term rubber mixing. For the continuous production of the factory, the wear of the internal mixer is a problem that cannot be ignored. This article mainly studies the wear of the end face of the internal mixer. The end face of the mixer is connected to the mixing chamber. With the increase in mixing time, the end face of the mixer is inevitably worn. The abrasion of the end face of the internal mixer causes the gap between the end face of the internal mixer and the mixing chamber to increase, and the materials in the mixing chamber leak out. This affects the ratio of materials and reduces the mixing effect. And with the increase in material leakage, the abrasion of the end face of the internal mixer is intensified, which eventually leads to a decrease in the compound's performance. BF is a pure natural inorganic non-metallic material. It has good high-temperature resistance, and high compressive strength can be used in various environments and is inexpensive and cost-effective. Based on this, BF is increasingly used in the rubber field. In this paper, the effect of adding different amounts of BF on the friction and wear of the end face of the internal mixer is studied, and the proportions of varying wear forms are distinguished for the first time. The study finds that with the increase of BF in the compound, the proportion of abrasive wear first decreased and then increased, the balance of corrosion wear first increased and then decreased, and the amount of metal wear first decreased and then increased. It is found that the lowest wear of the rubber compound on the metal can be achieved when the amount of BF reaches 10 phr. When the BF amount increases, the corresponding amount of metal wear increases. • With the increase of mixing time, the end face of the mixer is inevitably worn. • This paper studied the effect of different BF additions on the friction and wear of metals. • It is found that the lowest wear of the rubber compound on the metal can be achieved when the amount of BF reaches 10 phr. [ABSTRACT FROM AUTHOR]

As a piece of high-intensity running equipment, the wear of an internal mixer determines the quality of rubber and its life. In general, the wear of an internal mixer is caused by the friction between the rubber and metal during the mixing process, and the most severe wear position is the end face of the equipment. In this paper, a mixture of multi-walled carbon nanotubes (MWCNTs) and carbon fibers (CFs) are added to rubber by mechanical compounding to obtain MWCNT/CF/carbon black (CB) composites. By investigating the synergistic mechanism of MWCNTs and CFs, we analyze the effect of the MWCNT/CF ratio on the frictional wear of metal on the end face of the internal mixer. At the microscopic level, MWCNTs and CFs form a spatial meshwork with CB particles through synergistic interactions. The CB particles can be adsorbed on the spatial meshwork to promote the dispersion of CB particles. In addition, the formation of oil film can be slowed down due to the spatial meshwork, which could hinder the spillage of aromatic oil. Meanwhile, the spatial meshwork serves as a physical isolation layer between the rubber and metal to reduce friction. Therefore, it dramatically impacts the dispersion degree of CB particles, the friction coefficient, the roughness of the surface, and the wear of metal. It shows that the synergistic effect of MWCNT/CF and CB particles is best when the CF content of the rubber matrix is 5 phr, showing the most stable spatial network structure, the best dispersion of CB particles, and minor wear on the end face of the internal mixer. [ABSTRACT FROM AUTHOR]