Grey relational analysis and surface texture analysis of Al-based metal matrix composites

Abstract

The investigation found that the incorporation of MoS2 particles as reinforcement in Al–4% Mg material results in an increase in density and microhardness. The composite with 4% Mg and 6% MoS2 exhibited the highest percentage increase in the density up to 8.04%, and the highest percentage increase in the microhardness value of up to 33% as compared to the pure Aluminium. The pin-on-disc wear test revealed that the wear loss of the Al–Mg alloy is reduced by adding MoS2 particles as reinforcement. The wear loss decreases by 16.03% for the composite with 4% Mg and 6% MoS2. SEM analysis showed that the composite with higher MoS2 content (6%) exhibits a smoother worn surface. However, WEDM machining of the composite materials at higher levels of peak current, pulse on time, and gap voltage resulted in poor surface quality with more craters and micro voids. The sliding distance (m) was found to be the most significant parameter for wear output parameters, contributing to 57.05%–59.08% of the materials in samples 1 to 5. Similarly, the pulse on time (μs) was the most significant parameter for WEDM output parameters, contributing 46.29%–80.33% for the materials in samples 1 to 5. The study concluded that the PM route is an effective method for producing Al–Mg–MoS2 composites, which can improve the wear resistance of the Al–Mg alloy, and that WEDM parameters need to be optimized to achieve a better surface finish.