Tribological performance optimization of Al6061-fly ash composites using the taguchi method and grey relational analysis

Abstract

The present study deals with the tribological work of Al6061-Fly Ash (FA) metal matrix composites and optimization of the tribological parameters using the Taguchi method linked with the Grey Relational Method. Fabricated samples of different compositions of the same composite were machined to standard dimensions as per the requirement of the tribological testing machine. An orthogonal array L27 was selected based on the literature study. Three factors (volume fraction, Load, sliding speed) considered at three levels for experiment and wear depth & coefficient of friction as system output. Accordingly, 27 experiments were conducted, and wear depth & coefficient of friction results were collected for optimization study. The Grey relational grade value calculated using grey relational analysis is used as a quality of function to study the behavior of AL-FA MMCs concerning both friction and wear characteristics. ANOVA analysis was carried out to identify the important parameters and percentage involvement of each parameter on the tribological behavior of Al-FA composites. It was observed that the load factor has the most vital contribution to wear and coefficient of friction of Al-FA MMC. Also, it was observed that interactions between the factors also have an important influence on tribological performance the experimental results and analysis results were validated using a confirmation test. Scanning electron microscopy (SEM) was used to study the wear mechanism of the composite samples.