Interfacial characteristics and wear performances of iron matrix composites reinforced with zirconia-toughened alumina ceramic particles

Abstract

Zirconia-toughened alumina ceramic particle (ZTAP)-reinforced high Cr cast Fe matrix composites (ZTAP/Fe composites) are promising advanced wear-resistant materials. However, due to wear and tear, the ceramic particles may shed from the Fe matrix because of their low interfacial bonding properties. In the present work, we investigated interfacial characteristics and abrasive wear behaviours of ZTAP/Fe composites. Results showed that sintering played a significant role in the formation of sintering necks and consequently affected both compressive strengths and porosities of ZTA ceramic preforms. Optimum compressive strength (44.3 MPa) and porosity (25.2%) were obtained when sintering was performed at 1350 °C for 1 h. Subsequently, ZTAP/Fe composites without evident defects were fabricated by infiltration casting. Scanning electron microscopy, electron probe microanalysis and transmission electron microscopy were also used to analyse the microstructures and phase constituents of the interfacial layers of composites. Effects of applied wear loads on the wear behaviour evolutions and wear mechanisms of composites were examined. Wear resistances of ZTAP/Fe composites were found to be 1.64–2.21 times as compared to the Cr15 specimen.