Effect of iron (Wt.%) on adhesive wear response of Al-12Si-1Cu-0.1Mg alloy in dry sliding conditions

The presence of iron leads to different types of intermetallics in Al-Si alloys, among them needle shaped β-phase (Al₅FeSi) can lead to variations in hardness of the Al-Si alloy which ultimately can affect the wear resistance of the alloy. In this paper, the effect of iron on wear behavior of cast Al-Si alloys has been reported. Sliding wear behavior of eutectic alloy Al-12Si-1Cu-0.1Mg was investigated in dry sliding conditions by using pin-on-disk test configuration against heat treated EN31 steel counter-surface at room temperature. Sliding wear behavior has been evaluated at four normal loads of 5, 20, 50 and 70 N and two sliding speeds, 2 m/s and 4 m/s. Worn pin surfaces were examined by scanning electron microscopy (SEM) for analyzing wear mechanisms. The wear mechanism has been found to be mild oxidative type at lower sliding speed of 2m/s for entire range of loads used in the study. Transition to severe metallic wear occurs at higher sliding speed of 4 m/s at normal load of 5 N. Hardness of the alloy increased with increase in iron addition primarily due to presence of needle shaped Fe-rich intermetallics but it leads to an increased wear rate.