Tribological characterization of Al6061/alumina/graphite/redmud hybrid composite for brake rotor application

Dry sliding tribological characterization of redmud particle-reinforced Al6061/alumina/graphite hybrid metal matrix composite (RM-AlHMMC) was investigated as per ASTM G99-05 using pin on disc experimental setup. Initially, hybrid composites were fabricated through stir casting process by varying the wt.% of redmud particle as 3, 7, and 11, and then the wear tests were carried out based on L₂₇ orthogonal array. The experimental results revealed that 11?wt.% RM-AlHMMC showed maximum of 90% improved wear resistance than AlHMMC. For all the composites, the coefficient of friction (CoF) increases and saturates with the applied load and sliding distance, in which 11?wt.% RM-AlHMMC showed maximum of 48% increased CoF than AlHMMC. Metallographic investigation of worn-out AlHMMC composite showed that at maximum applied load, sliding velocity, and sliding distance, the wear mechanism changes from abrasive to adhesive, but adding of redmud particle showed combined adhesive and abrasive wear mechanisms. The optimized tribological parameters were obtained using grey relational analysis which revealed that 11?wt.% RM-AlHMMC has improved tribological properties.     

Analysis of tribological behaviour of aluminum-titanium carbide-basalt metal matrix composite

In the recent years, particulate reinforced aluminum based matrix composites are playing an important role in automobile and aerospace applications due to their enhanced properties. In this work, an attempt has been made to optimize the tribological behaviour of aluminum 7075 matrix reinforced with titanium carbide (3 percent weight) and basalt particles (2 percent weight) using Taguchi based grey relational analysis. Composites are fabricated according to american society for testing materials standard using stir casting method dry sliding wear tests were carried out using pin on disc apparatus as per Taguchi's L9 orthogonal array. Grey relational analysis was used to obtain the optimum process parameters for multiple quality characteristics such as wear rate and coefficient of friction. Then significant contribution of wear parameters was determined by analysis of variance. A confirmatory test was carried out to validate the test result. Finally, the micro structural investigation on the worn surfaces was performed by scanning electron microscope.     

Optimization of dry sliding wear parameters of AA336 aluminum alloy-boron carbide and fly ash reinforced hybrid composites by stir casting process

Boron carbide (10 wt%) and fly ash (5 wt%) particles are reinforced in AA336 aluminium alloy by stir casting process. Microstructure of samples are investigated and dry sliding wear factors viz., load (10 N–50 N), sliding distance (500 m–2500 m) and sliding velocity (1 ms⁻¹–5 ms⁻¹) are considered. Response surface methodology is used to design the experiments and wear weight loss of samples is measured. Regression equation is developed to predict the weight loss. Analysis of variance, significance test and confirmation test are used to find the significant wear parameters which affects the weight loss and the wear factors are optimized for obtaining lowest weight loss. Microstructure of samples showed uniform dispersion of particles in AA336 aluminium alloy. Wear test results showed that weight loss increased with increasing load and sliding distance. However, weight loss of samples decreased with increasing sliding velocity. Optimum dry sliding wear factors are found to be a load of 18.1 N, sliding distance of 905.4 m with a sliding velocity of 4.18 ms⁻¹.     

Fabrication of light-weight Al LM13/TiS2 metal matrix composites and investigation of its wear characteristics

This paper aims to study the dry sliding wear characteristics of LM13 aluminum alloy matrix containing titanium disulfide (TiS₂) as the reinforcement (10?wt%, average size 37?µm) fabricated through liquid metallurgy route. Microstructural examination and Vickers hardness test were performed on the sample to investigate uniform distribution of the reinforcement particles in the composite. Energy Dispersive X-Ray Analysis and X-Ray Diffraction techniques were used to characterize the composite. The hardness test gave a result of 105.94 HV. The dry sliding wear experiments were designed by a five-level central composite design developed using response surface methodology. The factors considered were load, sliding distance, and velocity which were varied in the range of 10–30?N, 500–1500?m, and 1–3?m/s, respectively. The experiments were then performed at room temperature using a pin-on-disc tribometer for 20 combinations. The generated regression equation showed that the developed model established a proper relation between the process variables and the response. Load being the most influential factor showed increasing trends of wear rate in the surface plots against both velocity and sliding distance. The wear rate exhibited a nonlinear trend in the surface plots against sliding distance and velocity. Scanning electron microscopy results showed greater wear at higher loads due to higher surface damage. Thus, the fabricated Al/TiS₂ composite with the optimum wear process parameters can be well utilized for application where wear becomes a major consideration.     

Experimental optimization of dry sliding wear behavior of in situ AlB2/Al composite based on Taguchi’s method

A wear rate prediction model for aluminum based composites reinforced with 10 and 30 wt.% in situ aluminum diboride (AlB₂) flakes was developed using Taguchi’s method by considering the parameters of sliding velocity, normal load, sliding distance and reinforcement ratio. Having produced the in situ reinforced bulk of composite, the final shape of the test samples was given through squeeze casting method. The wear behavior of the specimen was investigated using pin-on-disk rig where the samples sliding against a steel disk under different conditions. The orthogonal array, signal-to-noise ratio (S/N) and analysis of variance (ANOVA) were employed to study the optimal testing parameters on composite samples. The experimental results demonstrate that the normal load and reinforcement ratio were the major parameters influencing the specific wear rate for all samples, followed by sliding velocity. The sliding distance, however, was found to have a negligible effect on the specific wear rate. Moreover, the optimal combination of the testing parameters has been predicted. The predicted specific wear rates for all the test samples were found to lie close to that of the experimentally observed ones.     

Mechanical and tribological properties of LM13/TiO2/MoS2 hybrid metal matrix composite synthesized by stir casting

This paper involves the fabrication of LM13/TiO₂ (12?wt%)/MoS₂ (3?wt%) hybrid metal matrix composite and unreinforced alloy using liquid metallurgy route and evaluation of mechanical properties and adhesive wear characteristics. Microstructural investigation revealed homogeneous distribution of reinforcements in matrix. Hardness and tensile properties revealed that the composite had attained an improvement of 16.5 and 35%, respectively, over alloy. Wear characteristics were analyzed using pin-on-disk tribometer by varying load (10–40?N), sliding velocity (1–4?m/s), and sliding distance (500–2000?m). Statistical analysis was performed using response surface methodology to obtain the optimum wear process parameters for achieving maximum wear resistance. Results revealed that, with increasing load and sliding velocity, an increment in wear rate was observed for both alloy and composite, while a decline was observed with increasing sliding distance for composite and vice versa for alloy. Worn surface analysis revealed that load plays a prominent role in deciding wear rate, followed by sliding velocity. Sliding distance had less effect on wear rate of composite while it had significance on alloy. This hybrid composite can replace the conventional material used in automotive applications involving tribological importance.     

Comparative analysis of wear behavior of garnet and fly ash reinforced Al7075 hybrid composite

Al7075 hybrid composites reinforced with varying weight percentage (0 wt.%, 5 wt.%, 10 wt.%, 15 wt.%) of each of garnet and fly ash were fabricated and characterized for their comparative wear assessment. The sliding wear test was conducted on a reciprocating tribometer in dry medium under the working conditions of applied normal load (2 N, 4 N, 6 N, 8 N), sliding velocities (0.04 m/s, 0.08 m/s, 0.12 m/s, 0.16 m/s), sliding distance (20 m, 40 m, 60 m, 80 m) and working temperature (25 °C, 50 °C, 75 °C, 100 °C). The experiments were performed as per steady‐state condition and Taguchi (L₂₅) orthogonal array design to evaluate specific wear rate of the Al7075 hybrid composites. The finding of results indicated that the wear rate was decreased with the increase in the filler content in both the case of garnet and fly ash reinforced Al7075 hybrid composites. The results from Taguchi experiments suggested that the filler content and load were the most significant factors affecting wear behavior of composites while temperature and sliding distance are the least significant factors. Also, the garnet reinforced Al7075 hybrid composite indicated less specific wear rate as compared to that of fly ash reinforced Al7075 hybrid composite.     

Fabrication of 6061 aluminum alloy reinforced with Si3N4/n-Gr and its wear performance optimization using integrated RSM-GA

In this research work the dry sliding wear behavior of a hybrid aluminum metal matrix composite is evaluated. Al 6061 is used as a matrix material while Si₃N₄ and nanographite powder (3–15 wt%) are used as reinforcements. These two reinforcements (50 wt% of each) were blended in a high-energy ball mill for homogeneous mixing to derive the sound aluminum matrix composite (AMC). The hybrid composite is made by the stir casting route and its wear rate was investigated against an EN32 steel disc surface, using a pin-on-disc tribometer. Integrated response surface methodology (RSM) and genetic algorithm (GA) are used to optimize the pin-on-disc process parameters. Analysis of variance (ANOVA) shows that sliding distance plays a major role on the dry sliding wear rate followed by load, sliding speed and reinforcements. Two-factor interactions and quadratic terms have also significant contributions. GA suggested a minimum wear rate value of 0.827 mg at optimized setting. Microstructural analysis by scanning electron microscopy (SEM) reveals that very fine grooves are obtained at optimized settings while at other settings severe ploughing is observed. Transition of wear mechanism takes place with the increase of speed (i.e., temperature between the two rubbing surfaces) from abrasive to adhesive.     

Optimization of tribological parameters in abrasive wear mode of carbon-epoxy hybrid composites

Abrasive wear performance of fabric reinforced composites filled with functional fillers is influenced by the properties of the constituents. This work is focused on identifying the factors such as filler type, filler loading, grit size of SiC paper, normal applied load and sliding distance on two-body abrasive wear behaviour of the hybrid composites. Abrasive wear tests were carried on carbon fabric reinforced epoxy composite (C-E) filled with filler alumina (Al₂O₃) and molybdenum disulphide (MoS₂) separately in different proportions, using pin-on-disc apparatus. The experiments were planned according to Taguchi L18 orthogonal array by considering five factors, one at two levels and the remaining at three levels, affecting the abrasion process. Grey relational analysis (GRA) was employed to optimize the tribological parameters having multiple-response. Analysis of variance (ANOVA) was employed to determine the significance of factors influencing wear. Also, the comparative specific wear rates of all the composites under dry sliding and two-body abrasive wear were discussed. The analysis showed that the filler loading, grit size and filler type are the most significant factors in controlling the specific wear rate of the C-E composite. Optimal combination of the process parameters for multi performance characteristics of the composite under study is the set with filler type as MoS₂, filler loading of 10 wt.%, grit size 320, load of 15 N and sliding distance of 30 m. Further, the optimal parameter setting for minimum specific wear rate, coefficient of friction and maximum hardness were corroborated with the help of scanning electron micrographs.     

Investigations on dry sliding wear behavior of in situ casted AA7075–TiC metal matrix composites by using Taguchi technique

High strength 7075 aluminum matrix composites with 4 and 8 wt.% of TiC particulate reinforcement was synthesized by reactive in situ casting technique. X-ray diffraction analysis and scanning electron microscopy were used to confirm the presence of TiC particles and its uniform distribution over the aluminum matrix. The dry sliding wear behavior of the as-casted composites was investigated based on Taguchi L₂₇ orthogonal array experimental design to examine the significance of reinforcement quantity, load, sliding velocity and sliding distance on wear rate. The combination of 4 wt.% of TiC, 9.81 N load, 3 m/s sliding velocity and 1500 m sliding distance was identified as the optimum blend for minimum wear rate using the main effect plot. Load and sliding velocity were identified as the highly contributing significant parameters on the wear rate using ANOVA analysis. Further a confirmation test was also conducted with the optimum parameter combination for validation of the Taguchi results.     

Dry sliding wear behavior of heat treated hybrid metal matrix composite using Taguchi techniques

Dry sliding wear behavior of zinc based alloy and composite reinforced with SiCp (9 wt%) and Gr (3 wt%) fabricated by stir casting method was investigated. Heat treatment (HT) and aging of the specimen were carried out, followed by water quenching. Wear behavior was evaluated using pin on disc apparatus. Taguchi technique was used to estimate the parameters affecting the wear significantly. The effect of HT was that it reduced the microcracks, residual stresses and improved the distribution of microconstituents. The influence of various parameters like applied load, sliding speed and sliding distance on wear behavior was investigated by means and analysis of variance (ANOVA). Further, correlation between the parameters was determined by multiple linear regression equation for each response. It was observed that the applied load significantly influenced the wear volume loss (WVL), followed by sliding speed implying that increase in either applied load or sliding speed increases the WVL. Whereas for composites, sliding distance showed a negative influence on wear indicating that increase in sliding distance reduces WVL due to the presence of reinforcements. The wear mechanism of the worn out specimen was analyzed using scanning electron microscopy. The analysis shows that the formation and retention of ceramic mixed mechanical layer (CMML) plays a major role in the dry sliding wear resistance.     

Prediction of mechanical properties and modeling on sliding wear behavior of LM25/TiC composite using response surface methodology

Aluminum LM25/TiC (10?wt%) metal matrix composite was developed using the liquid metallurgy route. The microstructural examination and the mechanical properties such as hardness and tensile strength were investigated on the composite specimens. The tribological behavior of the composite was studied using central composite design (CCD) based on response surface methodology (RSM) under the influence of wear process parameters such as applied load, sliding velocity and sliding distance. Pin-on-disc tribometer was utilized for conducting the experimental runs and the model was constructed based on the obtained wear rates. Confirmation experiments and analysis of variance were performed to ensure the adequacy of the constructed model. Microstructural examination reveals that uniform dispersion was attained in the composite, which enhances the hardness and the tensile strength. The wear results showed that the wear rate increased with increase in load, decreases with increase in velocity and varies nonlinearly with sliding distance. Scanning electron microscopic (SEM) analysis was performed to examine the worn surface morphologies and the worn surfaces revealed that TiC reinforcement protects the matrix from more material removal at all conditions. The developed composite can be utilized for the tribological applications like engine block, cylinder liners and pistons.     

聚丙烯腈填充聚四氟乙烯复合材料摩擦磨损性能研究EI

用机械共混、冷压成型和空气中烧结的方法制备了不同质量分数的聚丙烯腈填充聚四氟乙烯制品。用MM-200摩擦磨损试验机测试不同样品在干摩擦下的摩擦学行为;用扫描电子显微镜和光学显微镜对几种样品的磨损面、磨屑和转移膜进行观察和分析。结果表明,聚丙烯腈的加入,不但使聚四氟乙烯的磨损量大幅降低,而且还使其摩擦系数有所降低。通过扫描电子显微镜观察发现填充聚丙烯腈的聚四氟乙烯样品的对磨面有完整而且不易脱落的转移膜,这是其具有良好耐磨性的主要原因。     

Wear Studies on Metal Matrix Composites: a Taguchi Approach

1. IntroductionDiscontinuously reinforced aluminium metal matrixcomposites (DRAMMCs) are a class of composite materi-als, which have desirable properties including low density,high specific stiffness, high specific strength, controlledco-efficient of thermal expansion, increased fatigue re-sistance, superior dimensional stability at elevated tem-peratures etc[1]. The most commonly employed metalmatrix composite system consists of aluminium alloy re-inforced with hard ceramic particles usuall…     

Dry sliding wear behaviour of zinc oxide reinforced magnesium matrix nano-composites

The main objective of the present work is to investigate the dry sliding wear behaviour of a magnesium matrix composite reinforced with zinc oxide nano-particles. Magnesium matrix composites have many applications, especially in the automotive and aerospace industries, due to their superior specific properties. A magnesium matrix composite with 0.5 vol.% ZnO nano-reinforcement was prepared using powder metallurgy and was hot extruded to eliminate pores. The wear behaviour of the Mg/ZnO nano-composite was investigated by conducting dry sliding tests as a function of wear with an oil-hardened non-shrinking (OHNS) steel disc as the counterpart on a pin-on-disc apparatus. Wear tests were conducted for normal loads of 5, 7.5 and 10 N at sliding velocities of 0.6, 0.9 and 1.2 m/s at room temperature. The variations of the friction coefficient and wear rate with the sliding distances (500 m, 1000 m and 1600 m) for different normal loads and sliding velocities were plotted and analysed. To study the dominant sliding wear mechanism for various test conditions, the worn surfaces were analysed using scanning electron microscopy. The wear rate was found to increase with the load and sliding velocity.     

Sliding wear of Al2O3P/6061 Al composite

The mild sliding wear behaviour of a 15 vol % Al₂O_3P/6061 Al composite has been investigated by using a pin-on-disc reciprocating sliding machine. The composite has been shown to exhibit an excellent wear resistance as compared to the unreinforced matrix alloy. The wear rate of the composite under dry wear conditions with a 12N load is approximately one tenth of that in the 6061 aluminium alloy. The wear rate of the composite under lubrication with 15W/40 gear oil under a 100N load is only one thousandth ofthat in the 6061 aluminium alloy.The dry wear resistance of an over-aged sample is shown here to be better than a peak aged or under-aged sample when the composite was aged at 160°C. The coefficient of friction of the composite was approximately 0.5–0.6 under dry conditions and 0.07 in lubricated wear experiments.In the initial stage, the worn surface of the composite under dry conditions is primarily composed of ploughed grooves and ductile tear. The composite makes a conducting contact with the steel pin. The worn surface is composed of compacted powder and the contact potential gradually increases when the period of the wear experiment goes beyond 2 h.     

Study on three-body abrasive wear behavior of functionally graded Al/TiB2 composite using response surface methodology

Functionally graded LM13 Al/10?wt% TiB₂ metal matrix composite has successfully produced under centrifugal casting. Hollow cylindrical composite with dimensions 150?×?150?×?15?mm was produced under rotating centrifugal speed of 1100?rpm. Microstructural characteristics were studied on the composite surfaces at distance of 1, 5.5, and 10?mm from outer periphery of the casting, and the results revealed that surface at distance of 1?mm has presence of more reinforcement particles. An objective of this study was to characterize abrasion wear behavior at the composite surfaces using dry abrasion tester. Mathematical models were developed using response surface methodology to study the relationship of parameters such as load, speed, and distance from outer periphery with abrasion wear rate. Face centered Central Composite Design with 20 experiments was preferred for dry abrasion test. Adequacy of model was predicted through analysis of variance, and the significance test result shows that load has major impact on the wear rate. The optimized parametric condition to obtain minimum wear rate was found as load of 33?N, speed of 112?rpm, and distance of 1?mm from outer periphery. Scanning electron microscopy analysis done at worn out surface showed maximum wear resistance at the outer periphery.     

热处理对Al2O3f+Cf/ZL109混杂复合材料干滑动摩擦磨损性能影响的统计学研究

利用挤压铸造法制备了Al₂O_3f+C_f/ZL109短纤维混杂增强金属基复合材料,并利用统计学方法对比研究了在滑动速度为0.837 m/s、压力为196 N的条件下热处理对该混杂复合材料干摩擦磨损性能的影响。研究结果表明:铸态和热处理态复合材料的磨损率和摩擦系数均服从正态分布,铸态复合材料的磨损率和摩擦系数均值都大于热处理态复合材料,热处理有利于复合材料摩擦磨损性能的提高。铸态复合材料的磨损机制主要为犁沟磨损和层离,热处理后复合材料抗层离的能力增强,磨损机制主要为轻微的犁沟磨损。     

Studies on sliding wear characteristics of aluminium LM25/silicon dioxide functionally graded composite and optimisation of parameters using response surface methodology

This paper deals with the study of dry sliding wear of LM25/silicon dioxide (10 wt.%) functionally graded composite. The composite was fabricated using stir casting technique and the melt was poured into a horizontal centrifugal die rotating at 1200 min^?1. After casting, the specimen (length 150 mm, external diameter 150 mm and internal diameter 130 mm) was subjected to microstructure and hardness tests at three different depths from the outer periphery (1 mm, 8 mm and 13 mm). The results of the respective tests revealed that the outer periphery of the specimen had higher particle concentration and hardness. Then, wear test was done on a pin‐on‐disc tribometer at room temperature with the experiments designed using response surface methodology and by taking specimens of size 8 x 8 x 15 mm such that the surface undergoing wear was at 1 mm from the outer periphery of the cast. The process variables of load (10 ‐ 40 N), velocity (1 ‐ 4 m/s) and sliding distance (400 ‐ 1200 m) were varied using a level 5 design and experiments were carried on for 20 different optimal combinations. From the regression equation generated for the wear response, it was found that load had maximum effect on the wear rate. The confirmation experiments proved that the regression model could serve well in predicting the wear rate for the given ranges of the continuous factors, for the given composite. Surface plots showed that the wear rate had an increasing trend with respect to load, which was the dominating continuous factor. Though the wear rate increased, severe delamination of the functionally graded composite was delayed. The optimum levels of the continuous factors to minimize the wear rate were found using response optimisation and found to be 10 N, 1.7576 m/s and 2000 m respectively. Scanning electron microscopy analysis of the worn surface of the specimens connected to the obtained trends and thus further validated the model developed. Thus, a functionally graded LM13 composite with silicon dioxid reinforcements is developed and a wear model to predict its wear rate under different process parameters is proposed with predictions of optimal performance conditions. This composite can increase life of components of wear applications in aerospace and automobile industry.     

Effect of oil and oil with graphite on tribological properties of glass filled PTFE polymer composites

Present work deals with the experimental investigation of tribological properties of GF-filled polymer composites considering three velocities, i.e. 0.5, 1 and 2.0 m/s and loads ranging from 15.7 N to 45.13 N keeping rest of the parameters constant. The test has been carried out for three materials, PTFE + 15% GF, PTFE + 25% GF and PTFE + 35% GF in wet (oil) and adding additive as graphite (5% wt) in oil. SAE 20W40 oil is used for the test. Friction and wear tests of PTFE composite against a counter surface of EN8 with surface finish of 0.56 μm are carried out at ambient conditions using pin-on-disc tribometre (TR-20), Ducom make, Bangalore. The results are tabulated and graphs are plotted. It has been found that load and wet conditions have significant effect on coefficient of friction and specific wear rate of the materials. Where as sliding velocity also plays little role in wear mechanism of the material. It is concluded from the experimental study that the specific wear rate in wet condition as well as by adding additives in lubricating oil with 5% (by wt.) has been declined. Also the specific wear rate decreases with normal load and sliding velocity. Wear of PTFE + GF composite decreases with increase in glass percentage. Microscopic analysis of pin and disc surface is made with optical microscope. The mathematical models has been developed by using regression analysis and found to be valid for the above tested parameters.