Fabrication of WS2 Dispersed Al-Based Hybrid Composites Processed by Powder Metallurgy: Effect of Compaction Pressure and Sintering Temperature

Abstract

In recent years, aluminium-based hybrid composites acquire vast potential in the hot reciprocating parts such as piston, connecting rod for petrol and diesel engines in automobiles due to its suitable mechanical and physical properties. On the other hand, these composites limit its application due to the inferior tribological properties. Aluminium-based ceramic composites with improved lubrication behavior enhance their application in various sectors. In the present study, an attempt has been given to fabricate Al–Al2O3–WS2 hybrid composites using the powder metallurgy method by optimizing the processing conditions. The samples were fabricated with varying the compaction pressure (380 MPa, 450 MPa, 500 MPa, 560 MPa, and 620 MPa) and sintering temperature (400 °C, 500 °C, and 600 °C). The densities and porosity of the samples were measured by both theoretical and experimental methods. X-ray diffraction and scanning electron microscopy were used to study the structural and morphological changes and hardness of the samples was measured using Vicker’s microhardness tester. From the above investigations, it was found that with a compaction pressure of 560 MPa and a sintering temperature of 600 °C, the as-fabricated Al–Al2O3–WS2 hybrid composite shows better properties as compared to unreinforced aluminium alloy. This study will provide a guideline to select the processing conditions for the fabrication of hybrid composites using a powder metallurgy process.