Wear Resistance Mechanism of Polyaspartic

The wear resistance of polyaspartic is a key advantage that enables its durability under conditions of high mechanical stress, particularly in industrial flooring, parking lots, and logistics warehouses. Its wear resistance results from an integrated approach involving chemical structural design, physical performance optimization, and functional modifications.

Chemical Structure and Molecular Basis of Wear Resistance

1.High Crosslink Density

• Polyaspartic forms a three-dimensional crosslinked network through the reaction between isocyanates and aspartic esters. The small spacing between crosslinks (nanometer scale) creates strong intermolecular forces, forming a rigid "reinforcing mesh" that resists molecular chain breakage due to friction.
• Comparative crosslink density: Polyaspartic's crosslink density is 3-5 times higher than traditional epoxy resins, significantly enhancing surface hardness (Shore D 70-85).

2.Synergy of Hard and Soft Segments

• Hard segments: Carbamate segments (-NH-CO-O-) formed by the reaction of isocyanates and aspartic esters provide rigid structural support.
• Soft segments: Polyether or polyester segments (e.g., PTMG) provide elasticity, absorbing impact energy to prevent brittle wear.
• Synergistic effect: Hard segments resist surface scratches, while soft segments distribute stress, reducing fatigue wear.

3.Molecular Chain Orientation

During curing, molecular chains align orderly along the stress direction, forming a "self-reinforcing" structure that enhances resistance to shear and abrasive wear.

Physical Properties and Functional Modification

1.Balance of High Hardness and Toughness

• Hardness: Shore D 70-85 (traditional epoxy resins: D 60-70), comparable to hard plastics like nylon, effectively resisting metal tool scratches.
• Toughness: Elongation at break >300%, avoiding brittle chipping common in ceramic coatings under impact.

2.Reinforcement with Functional Fillers

• Quartz sand (SiO₂): Adding quartz sand (particle size 80-120 mesh) increases surface hardness, reducing Taber abrasion to below 20mg.
• Silicon carbide (SiC): Nano-sized silicon carbide particles fill crosslinked network pores, reducing friction coefficient (μ <0.4).
• Anti-wear additives: Polytetrafluoroethylene (PTFE) or molybdenum disulfide (MoS₂) reduce surface friction, creating a "self-lubricating" effect.

3.Surface Density

Solvent-free formulations and rapid curing result in a non-porous surface, preventing abrasive particles from embedding and causing accelerated wear.

Empirical Data on Wear Resistance

1.Taber Abrasion Test (ASTM D4060)

• Polyaspartic: CS-10 wheel, 1000g load, less than 40mg wear after 1000 cycles.
• Epoxy resin: Greater than 100mg under identical conditions.
• Concrete: Greater than 500mg.

2.Sand Abrasion Test (ASTM D968)

Polyaspartic coatings require >50L of sand to wear through 1mm thickness, triple that of conventional epoxy coatings.

3.Practical Field Verification

• Case 1: Automotive manufacturing workshop floor had surface wear depth <0.1mm after 3 years (200 forklift passes/day).
• Case 2: Airport cargo area flooring required no maintenance for 10 years, with no dusting or peeling.

Comparison with Traditional Materials

Optimization Strategies for Wear Resistance

1.Formulation Design

• Filler gradient distribution: Coarse quartz sand at the base layer (compression resistance), nano SiC at the top layer (wear resistance).
• Toughening modification: Introducing elastomers (e.g., PU prepolymers) enhances impact resistance and avoids fatigue wear.

2.Application Process

• Multi-layer coating: Primer (base sealing) + intermediate coat (quartz reinforcement) + topcoat (smooth wear-resistant layer).
• Surface preparation: Shot blasting or grinding base surface to grade Sa2.5 (GB 8923-2011), ensuring adhesion >5MPa.

3.Environmental Adaptation

• High-temperature environments: Incorporate heat-resistant fillers (e.g., ceramic microspheres) to prevent softening and accelerated wear.
• Low-temperature environments: Use polyether segments with low glass transition temperature (Tg) to maintain toughness at low temperatures.

Failure Modes and Solutions

1.Surface Scratches

Cause: Hard particles (e.g., metal shavings) causing scratches.

Solution: Regular cleaning; add PTFE to reduce friction.

2.Fatigue Wear

Cause: High-frequency cyclic loads causing molecular chain breakage.

Solution: Increase crosslink density or introduce dynamic crosslinking bonds (e.g., Diels-Alder bonds) for self-repair.

3.Chemical Corrosion Wear

Cause: Acidic or alkaline substances corroding the coating surface.

Solution: Add fluorocarbon resin to enhance chemical resistance.

The wear resistance of polyaspartic is a result of its highly crosslinked network, synergistic hard-soft segments, and functional filler reinforcement. With optimized molecular design and engineered modifications, its wear performance can surpass traditional materials by 3-5 times, making it ideal for high-wear scenarios. Advances in self-repair technology and nano-composites will further enhance its durability and adaptability in the future.

Feiyang has been specializing in the production of raw materials for polyaspartic coatings for 30 years and can provide polyaspartic resins, hardeners and coating formulations.

Feel free to contact us: marketing@feiyang.com.cn

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• Polyaspartic Resin
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• Special Chemical

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