Enhancing the capabilities of Mg–4Zn-1RE-0.7Zr alloy through synergistic integration of ceramic (ZrO2) & solid lubricant (BN/MoS2) reinforcements: A Taguchi-GRA optimization approach

Abstract

In this present investigation, novel hybrid magnesium composites were synthesized by the inclusion of self-lubricating (BN/MoS2) and ceramic (ZrO2) particulates with the help of the powder metallurgy technique. ZE41 magnesium (Mg–4Zn-1RE-0.7Zr) was applied for a broad range of components, including the gearbox casing, the framework of the door, and transmission in aircraft like the Sikorsky UH-60 and the Boeing 727. Apart from its structural application, its usage was limited because of its deficient wear and mechanical properties. This research focuses on enhancing the potential applications of the ZE41 magnesium alloy by improving its mechanical and tribological characteristics. The design of the experiment scheme was applied to explore the effect of individual reinforcements and their synergistic effects on various properties of prepared composites. Microstructural inspection was employed to inspect the morphological characteristics of prepared specimens through scanning electron microscope (SEM) and Energy-dispersive X-ray spectroscopy (EDS) and X-ray diffraction analysis (XRD). By analysing SEM, EDS, and X-ray diffraction patterns, the microstructural evaluation reveals uniform phase dispersion and the existence of reinforcements with some minor defects. As a result of the inclusion of reinforcements in composites, the hardness of the reinforced specimen improved to 39.65%, while the wear rate of the reinforced specimen decreased to 40.90% compared with monolithic alloy. A multi-objective grey relational analysis (GRA) optimization method was used to perform a detailed tribological analysis on Specimen G (ZE41 mg + 3% ZrO2 + 3% MoS2). According to the results of GRA, the optimized rate of wear and frictional coefficient were achieved on sliding velocity (4 ms−1), sliding distance (2000 m), and load (10 N). The worn surface micrograph reveals that the reinforced composite underwent abrasion and delamination wear, while the unreinforced alloy experienced plastic deformation.