This research project aimed to test the mechanical properties and the capability in wear resistance of ultra-high molecular weight polyethylene composite as well as determine the optimal formulation of UHMWPE-based composites which had a main component of aluminum oxide. The developed formula was used in the manufacture of run-flat wheels and thus applied to build run-flat wheels with an understanding of the proper molding conditions under the run-flat wheel forming process. Two materials used in the research consisted of super-high molecular weight polyethylene (UHMWPE) as the base material and the additive of aluminum oxide (Al2O3). The parameters employed in the hot compression process to obtain the specimen for the experiment consisted of compressive force temperature time and the ratio between super-high molecular weight polyethylene and aluminum oxide. The test for mechanical properties consisted of an impact test a hardness test according to the ASTM D2240 standard a tensile test according to the ASTM D638 standard type I and a wear test according to the ASTM G77 standard. The results indicated that a hot compression condition under a pressure of 5 MPa a temperature of 210°C for 90 min and using 5% Al2O3 HTM 30 material caused mixed uneven powder particle sizes between 2 to 5 µm. The tensile test results inferred the yield strength of 20.52 MPa ultimate tensile strength at 29.96 MPa breaking strength at 22.83 MPa elongation at break at 265.8% and modulus of elasticity at 784.46 MPa. The highest hardness was 62 shore D the high impact strength was 586.8 J/m and it was displayed for the wear rate of hot compression specimens made of UHMWPE mixed with 5% HTM-30. Moreover it introduced a coefficient of friction the wear rate and the density of 0.12 8.66E-11 mm3/N.m and 1.2446958 g/cm3 respectively.

In conducting the research on Material Science two composite materials ultra high molecular weight polyethylene (UHMWPE) powder and aluminum oxide (Al2O3) powder were formulated by hot compression molding process. The formulated materials demonstrated good mechanical properties and high wear resistance properties. Based on the studies the Al2O3 grade selected was Al2O3 HTM 30 harboring mixed uneven powder particle sizes ranging from 2 to 5 microns (μm) and selected proportion of Al2O3 alloy mixed for improving mechanical and wear resistance properties of the UHMWPE composite material was the UHMWPE+Al2O3 HTM 30 at a ratio of 95:5%. When considering both material properties and cost effectiveness in the impact test 2-5 μm Al2O3 HTM carried the higher impact strength than other aluminum oxide grades with the values up to 586.8 J/m at a ratio of 5% aluminum oxide. The hardness test of the 2-5 μm UHMWPE+ Al2O3 HTM delivered the hardness at 58.8 using the standard durometer. The tensile test values consisted of Yield Strength Ultimate Tensile Strength Breaking Strength Elongation at Break and Modulus of elasticity equal to 20.52 MPa 29.96 MPa 22.83 MPa 265.8% and 784.46 MPa respectively.