Wear resistant lubricious composite

1. A wear resistant lubricious composite, comprising:

(a) a continuous phase synthetic resin binder, wherein the continuous phase synthetic resin binder is selected from the group consisting of: a polyamide resin, a polyamide-imide resin, a polybenzimidazole resin, and a phenolic resin;

(b) a plurality of transfer film forming nanoparticles; and

(c) a plurality of hard nanoparticles,

wherein: (i) the transfer film forming nanoparticles and the hard nanoparticles are distributed in the continuous phase synthetic resin binder, and (ii) the continuous phase resin binder does not include a photo-initiator.

2. The composite of claim 1 , wherein the transfer film forming nanoparticles comprise PTFE.

3. The composite of claim 1 , wherein a wear rate of the composite is <1×10 −6 mm 3 /Nm and a friction coefficient of the composite is <0.2.

4. The composite of claim 1 , further comprising a base metal article, wherein the composition is disposed on the base metal article.

5. The composite of claim 1 , wherein the hard nanoparticles are selected from the group consisting of a metal oxide nanoparticle, a metal carbide nanoparticle and a metal nitride nanoparticle.

6. The composite of claim 5 , wherein the continuous phase synthetic resin binder is 80-99 volume % of the composition; wherein the plurality of transfer film forming nanoparticles is 1-18 volume % of the composition; the plurality of hard nanoparticles is 0.5-10 volume % of the composition.

7. The composite of claim 1 , wherein the transfer film forming nanoparticles are selected from the group consisting of a PTFE particle, a WS 2 nanoparticle, a MoS 2 nanoparticle, a boron nitride nanoparticle, and a fluorinated ethylene proplylene nanoparticle.

8. The composite of claim 7 , wherein the continuous phase synthetic resin binder is 80-99 volume % of the composition; wherein the plurality of transfer film forming nanoparticles is 1-18 volume % of the composition; the plurality of hard nanoparticles is 0.5-10 volume % of the composition.

9. The composite of claim 1 , wherein the continuous phase synthetic resin binder is 80-99 volume % of the composition; wherein the plurality of transfer film forming nanoparticles is 1-18 volume % of the composition; the plurality of hard nanoparticles is 0.5-10 volume % of the composition.

10. A method of forming wear resistant lubricious composite articles, the method comprising the steps of:

(1) providing a liquid phase synthetic resin precursor, wherein the synthetic resin precursor is selected from the group consisting of: a polyamide resin, a polyamide-imide resin, a polybenzimidazole resin, and a phenolic resin;

(2) adding a plurality of transfer film forming nanoparticles and a plurality of hard nanoparticles to the resin precursor to form a mixture, wherein

(i) the transfer film forming nanoparticles and the hard nanoparticles are distributed in the mixture, and

(ii) the mixture does not include a photo-initiator;

(3) adding a hardener to the mixture, and

(4) curing the mixture.

11. The method of claim 10 , further comprising the step of dispersing said transfer film forming nanoparticles and said plurality of hard nanoparticles after said adding step.

12. The method of claim 11 , further comprising the step of applying said mixture to a surface to be coated before said adding hardener step.

13. The method of claim 12 , wherein said surface to be coated comprises a metal or a metal alloy.

14. The method of claim 10 , wherein said transfer film forming nanoparticles comprise PTFE.

15. The method of claim 10 , wherein a wear rate of said composite is <1×10 −6 mm 3 /Nm and a friction coefficient of said composite is <0.2.

16. The method of claim 10 , wherein the hard nanoparticles are selected from the group consisting of a metal oxide nanoparticle, a metal carbide nanoparticle and a metal nitride nanoparticle.

17. The method of claim 16 , wherein the synthetic resin precursor is 80-99 volume % of the composition; wherein the plurality of transfer film forming nanoparticles is 1-18 volume % of the composition; the plurality of hard nanoparticles is 0.5-10 volume % of the composition.

18. The method of claim 10 , wherein the transfer film forming nanoparticles are selected from the group consisting of a PTFE particle, a WS 2 nanoparticle, a MoS 2 nanoparticle, a boron nitride nanoparticle, and a fluorinated ethylene proplylene nanoparticle.

19. The method of claim 18 , wherein the synthetic resin precursor is 80-99 volume % of the composition; wherein the plurality of transfer film forming nanoparticles is 1-18 volume % of the composition; the plurality of hard nanoparticles is 0.5-10 volume % of the composition.

20. The method of claim 10 , wherein the synthetic resin precursor is 80-99 volume % of the composition; wherein the plurality of transfer film forming nanoparticles is 1-18 volume % of the composition; the plurality of hard nanoparticles is 0.5-10 volume % of the composition.

21. The composite of claim 1 , wherein the continuous phase synthetic resin binder is a polyamide-imide resin.

22. The composite of claim 1 , wherein the continuous phase synthetic resin binder is a polybenzimidazole resin.

23. The composite of claim 1 , wherein the continuous phase synthetic resin binder is a phenolic resin.

24. The method of claim 10 , wherein the continuous phase synthetic resin binder is a polyamide-imide resin.

25. The method of claim 10 , wherein the continuous phase synthetic resin binder is a polybenzimidazole resin.

26. The method of claim 10 , wherein the continuous phase synthetic resin binder is a phenolic resin.