Morphology-regulated molybdenum disulfide/multi-walled carbon nanotubes hybrids for enhanced tribological and mechanical performance of polyether ether ketone composites

Polyether ether ketone (PEEK) exhibits exceptional thermal stability but faces limitations in mechanical and tribological performance under harsh environments. This study introduces MoS 2 /MWCNTs hybrid nanomaterials with controlled morphologies (nanoflowers vs. nanotubes) and varying mass ratios to synergistically enhance both friction reduction and mechanical robustness of PEEK composites. Through a one-step hydrothermal synthesis and hot-pressing technique, the MoS 2 nanotubes/MWCNTs hybrid (MMT-5) demonstrated optimal performance, achieving a 23.73 % reduction in friction coefficient (0.225) and an 88.95 % decrease in wear rate compared to pure PEEK. Notably, MMT-5 exhibited a 23.77 % increase in compressive strength (184.79 MPa) and a 5.36 % improvement in Shore hardness (90.08 HD), attributed to the synergistic effect of MWCNTs' 3D network and MoS 2 's lubricating properties. In anhydrous ethanol, MMT-5 achieved an ultra-low friction coefficient of 0.029 and wear rate of 9.06 × 10 −6  mm 3 /(N·m), driven by ethanol-mediated lubrication and graphitized transfer films. These results highlight the critical role of nanomaterial morphology and hybrid ratio in balancing tribological efficiency, mechanical strength, and thermal properties, offering a sustainable pathway for high-performance PEEK composites in aerospace, marine engineering, and heavy-load applications.