Abstract
Abstract A porous mullite ceramic, which was obtained via replica method using coal fly ash as the main starting material, was used as reinforcement preform to fabricate an A356/fly-ash-mullite interpenetrating composites by a three-stage schedule squeeze casting method. Different squeezing pressures (0, 40, 80 and 120 MPa) were applied during the fabricating processes. The optimal composite was obtained at 80 MPa with sound interfacial bonding and interpenetrating structure. Compared to the base A356 alloy, the optimal composite demonstrated increased wear resistance in the pin-on-disc wear tests. The wear rate of the optimal composite was less than half of the one of A356 alloy. In addition, steadier and larger frication coefficient was also achieved by the composite comparable to the A356 alloy. The composite has good potential for use as a wear-resistant braking material.
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