Wear Behaviour Of Aluminium Alloy Research Articles

Dry sliding wear behavior of aluminum alloy 6082 - SiC composites through ex-situ casting process

The applications of AA6082 alloys in the structural and transport are found to be more due its light weight. To improve strength to weight ratio and stress resistance, the carbides/oxides are added and this will leads to improvement in the mechanical properties and high stress sustainability. In this research work, AA6082 Metal Matrix Composite (MMC) is manufactured through the ex-situ casting process with the Silicon Carbide (SiC) reinforcements of 2.5 & 5 wt% and the microstructure evolution, hardness, dry sliding wear behavior and tensile properties of MMCs are investigated. As-cast AA6082 showed the dendritic microstructure with intermetallic eutectics. The presence of SiC particulates in AA6082 resulted in decreased grain size and equixed grains. The hardness of the tested as casted AA6082 samples was found to be 81 HV which has been increased to 93 HV and 107 HV and the tensile strength of AA6082 is increased by 16% and 41% by addition of 2.5 wt% SiC and 5 wt%SiC respectively due to the presence of the SiC particulates. At the same time coefficient of friction of AA6082 is found to be decreased by 11.8% and 20.5% for the testing load of 10N and the corresponding decrease in wear rates were found to be 50.8% and 70.3% respectively. The worn surface showed the continuous groove parallel to sliding direction with short cracks, bidirectional rough grooves with peeled-off SiC, unidirectional smooth scratches along the sliding surfaces for as-cast AA6082, AA6082-2.5 wt SiC and AA6082-5 wt SiC respectively that indicates the significant effects of SiC particulates on wear mechanism.

Wear behaviour of aluminium alloy 5083/SiC/fly ash inoculants based functional composites – optimization studies

The wear characteristics of Aluminium AA 5083/SiC/Fly Ash functional composites under different load conditions are an important aspect to assess the inoculation of Fly Ash for enhancing the functionality of the aluminium composites with respect to its tribological behaviour and its influence on wear properties. The present work is majorly aimed at the development of AA 5083/SiC functional composites inoculated with Fly Ash using stir casting method for different blends of the reinforcements (2.5, 5 & 7.5 wt%). The novelty of this research is majorly attributed to the incorporation of functional inoculants in the form of Fly Ash, which along with the SiC is bound to influence the tribological characteristics of the composites. The wear characteristics of these fabricated composites have been investigated considering various process parameters viz., the load, sliding distance, sliding velocity, wt% of SiC and wt% of Fly Ash, based on the operational requirements of the composites in real time considered from the earlier research studies and the influence of each parameter on the wear rate is discussed. Based on the different wear regimes obtained after characterization of the samples at different load conditions, Analysis of Variance (ANOVA) is carried out for each blend of the samples to statistically validate the experimental outcomes. The results have given sufficient substantiation to the fact that wear rate decreases with the inoculation. The wear rate and coefficient of friction (COF) is minimum viz., 0.00095 mm3/m, and 0.301 respectively for L9 experimental trial, i.e., for the composite specimens synthesized by reinforcing 7.5 wt% SiC, and 7.5 wt% Fly Ash for a load of 20 N, sliding velocity of 6 m s−1, and a sliding distance of 3000 m. The results have conferred that micro segregation (coring) of SiC and uniform dispersion of Fly Ash in the matrix enhances its tribological characteristics.

Wear Resistance of Aluminum Matrix Composites’ Coatings Added on AA6082 Aluminum Alloy by Laser Cladding

Ceramic-reinforced metal matrix composites are known for their high wear resistance. A coating based on these materials would be helpful to improve the wear behavior of aluminum alloys. Laser cladding has been used to deposit a coating consisting of an aluminum alloy reinforced with SiC particles on an AA6082 aluminum alloy. Laser cladding is a very energetic technique that causes the SiC particles to react with the molten aluminum to form Al4C3, which degrades the particles and reduces the properties of the coating. The formation of this detrimental compound was successfully achieved with the addition of Silicon and Titanium to the composite matrix. The microstructures of the newly developed material were characterized and the wear behavior was studied under dry sliding conditions on a pin-on-disc tribometer. The relationship between the microstructure and wear behavior was identified. The absence of Al4C3 in the Al40Si/SiC and Al12Si20Ti/SiC coatings’ microstructures resulted in an abrasion mechanism instead of a delamination mechanism. The wear behavior changed along the sliding distances. During the first 200 m of sliding distances, the wear rate of all coatings was lower than the uncoated one due to their higher microhardness. For longer sliding distances, the wear resistance of the uncoated AA6082 was higher than the coated ones due to the formation of a lubricant oxide layer on the AA6082 worn surface. For 1000 m of wear distances, the wear behavior was different for each coating. The wear rate of the Al12Si/SiC coating continued growing due to the delamination mechanism and the presence of Al4C3 that acted as starting crack points. The wear rate of the Al40Si/SiC coating decreased due to the formation of a thin, superficial oxide layer. The wear rate of the Al12SiTi/SiC progressively decreased along the sliding distance to below the substrate wear rate.

Microstructure and wear behaviour of aluminium surface composites fabricated using friction stir processing

In this study, wear behavior of AA6082 matrix composite reinforced with titanium carbide particles (TiC) produced by friction stir processing was investigated. The main objective of this study is to compare the microstructure and wear behavior of Aluminium alloy 6082 with AA6082-TiC surface composites. FSP was carried out using a threaded pin tool with 1200 rpm tool rotational speed, whose processing speed of 60 mm/min and an axial load of 10 kN. The microstructure analysis exhibited that the fine grains and uniform distribution of TiC particles in friction stir processed AA6082 matrix with and without TiC particles, respectively. A pin on disc equipment was used to study the wear properties. It was observed that the wear resistance of the FSPed aluminium composites samples improved significantly as compared to that of the AA6082 matrix alloy. With this the effect of TiC particles on worn surface and wear debris is also reported in this study.

Development of aluminum based AA 2014 and AA 7075 dissimilar metals for aerospace applications

The present study deals with the investigation of wear behavior of aluminum alloy. The material chosen for this study are AA2014 and AA7075. The two metals are joined together using friction stir welding. The Friction stir welding (FSW) process is a strong state joining process and the joining temperature is lower than that utilized in the combination welding forms. In this manner, for different metal welding, FSW is considered to offer a few focal points over combination welding. This study deals with the present examination centers around the impacts on tensile strength due to material position and device rotational speed. Material AA2014 and AA7075 material alloy are chosen for the welding process. The welded aluminum compounds are of a thickness of 6.0 mm in utilizing a traditional processing machine. The tried samples are inspected utilizing Scanning Electron Microscope (SEM) for the portrayal of microstructure and tribolayer on worn surface of composites. The outcomes uncover that wear pace of hybrid composite is lower than that of twofold composite. The wear rate diminished with the expanding load and sped up. The similar investigation uncovers that the proposed composites have lower erosion coefficient, less temperature rise and low noise level; anyway they have minimal higher wear rate. It is inferred that the hybrid composite has worthy degree of tribological attributes with blacky and smooth worn surface.

Wear behaviour of hot forged SiC reinforced aluminium 6061Composite materials

ABSTRACT The present work aims to investigate the effect of hot forging on the wear behaviour of aluminium alloy 6061 reinforced with silicon carbide (SiC) particles of size 25 to 30 µm. Forging of the specimens was done at a temperature of 430°C. The Al-SiC composites were prepared using stir casting technique. The weight fractions of reinforcement used were 2, 4 and 6 and the cast composites were forged for reduction ratios of 20%, 40% and 60%. The wear tests were conducted at a disc rotational speed of 800 rpm and loads of 30 N, 40 N and 50 N were used for sliding distances of 1000 m, 1500 m and 2000 m. The worn-out surfaces of the samples were analysed using scanning electron microscopy. It was found that the wear rate of the forged composites was lower compared to the unforged composites. Increasing the weight percentage of SiC particles in the matrix was found to enhance the wear resistance of the composite. It was observed that the wear rate increased with increasing load and the sliding distance.

Development, mechanical characterization and analysis of dry sliding wear behavior of AA6082–Metakaolin metal matrix composites

This work emphasized the preparation, mechanical characterization, and evaluation of dry sliding wear behaviour of Aluminium Alloy (AA) 6082 metal matrix composites reinforced with metakaolin particles. The reinforcement particles were incorporated in the aluminium matrix at an amount of 0% to 15% in terms of weight, in a step of 2.5%. Ultra-sonic cavitation assisted stir casting process was employed for the preparation of the composites and the prepared composites were subjected to T6 heat treatment. Optical micrographs were utilized to examine the dispersion of reinforcement particles in the matrix. The tensile properties were enhanced with an increase in the amount of the reinforcement particles up to 7.5 weight % and then started to degrade. The micro-hardness and wear behaviour also expressed a similar trend. The fractured surfaces were examined using a Scanning Electron Microscope (SEM). The pin-on-disc wear test was employed to characterize the wear behaviour of the composites. Wear rate and average coefficient friction of the prepared composites were analyzed by varying the significant parameters such as load, sliding velocity, and sliding distance. Field emission scanning electron microscope (FESEM) and energy dispersive spectroscopy (EDS) data were utilized to examine the worn-out surfaces. The T6 heat-treated specimens expressed remarkable enhancement in mechanical and wear properties compared to as-cast samples.

Effect of structural stiffness on impact-sliding wear behavior of aluminium alloy

Impact-sliding wear is a typical form of composite wear and occurs in many industrial equipment. The effects of structural stiffness on the impact-sliding wear damage and mechanisms of aluminum alloy were investigated using a bespoke impact-sliding device. The damage evolution and mechanisms of the impact-sliding wear for three different structural stiffness conditions were analyzed. Results showed that the main damage zone gradually shifted along the sliding direction with the increase in the structural stiffness. The wear damage of the material was higher for the low and high structural stiffness conditions and resulted in a very rough surface. However, for the medium structural stiffness, the impact-sliding wear exhibited a slow and linear increase and relatively smooth wear scars were observed. Moreover, the main wear mechanism transformed from delamination to ploughing as the structural stiffness increased.

Erosive wear behaviour of aluminium alloys: a comparison between slurry and dry erosion

The erosive wear performance of AA5083 and AA1050 has been investigated under dry and slurry erosion condition. The current work insights the erosive wear behaviour of Al alloys by changing the impact velocity and impingement angle. AA5083 exhibited remarkable erosion resistance compared to AA1050 by a factor of 2.5 to 3 in both the tests. The surface roughness of the eroded surface for impingement angle 15, 60° was an average of 450, 170 μm respectively for dry and slurry erosion test. Hardness of the eroded surface after the erosion test was measured to be 128.6 and 111.5 Hv for AA5083 and 63.9 and 52.9 Hv for AA1050 respectively for dry and slurry erosion. Wear surface studies reveals that cutting as well as abrasion grooves were dominant at lower impingement angle for both the tests. As the impingement angle increased, the material removal process was tuned by ploughing and formation of a crater in dry erosion and cracking in slurry erosion was witnessed. The subsurface study reveals that the affected region beneath the wear surface was an average of 40 and 25 μm for AA1050 and AA5083. Erosion data was correlated with the published empirical erosion model to analyse the dependence of the impingement angle.

Investigation on the wear behaviour of Aluminium alloys at cryogenic temperature and subjected to cryo -treatment

The published information on ferrous and nonferrous metals especially Aluminium alloys subjected to deep cryogenic treatment (DCT) have yielded much improved mechanical, tribological and thermal properties resulting in improved properties in the field. Keeping the above aspects in view, tribological studies have been taken up in this work with the main objective of evaluating the wear resistance of the most used Aluminium alloys viz: Al 2024, 6082 and 7075 samples at cryogenic temperature and subjected them to deep cryogenic treatment for 64 hrs. The novelty of the work lies in conducting the wear test in cryogenic atmosphere which is the first of its kind as meagre report is available. It is observed from the wear data that the slide wear resistance and coefficient of friction evaluated in the laboratory conditions show superior wear resistance for the load application of 40N and 50N and lower friction levels for the samples subjected to sliding at cryogenic temperature as well as for the samples deeply cryo treated compared to the untreated ones. The data have been substantiated by Scanning Electron Microscopic features (SEM).

Retraction notice to "Effect of heattreatment on the sliding wear behaviour of aluminium alloy (Al-Zn-Mg) hard particle composite" [Tribology International 43 1-2 (2010) 330-339 of retracted article

Retraction notice to "Effect of heattreatment on the sliding wear behaviour of aluminium alloy (Al-Zn-Mg) hard particle composite" [Tribology International 43 1-2 (2010) 330-339 of retracted article

Sliding Wear Properties of a Composite of Aluminum 2024 Powder Reinforced with Heat Treatment and Silicon Carbide

Wear behavior of aluminum alloy 2024 was investigated. Three patterns of specimens, namely, fabricated (compacted), reinforced with silicon carbide only and reinforced with silicon carbide followed by heat-treatment (quenching and aging processes) were selected. The effect of load on the specimen was studied for each type of pattern. Three values of load (10, 12.5 and 15N) were tested to investigate the wear behavior. The experimental results showed that the weight loss was 0.056 g for the specimen reinforced with silicon carbide and heat treatment, while it was 0.069 and 0.067 g for the as-fabricated specimen and the specimen reinforced with silicon carbide only, respectively. The increase of microhardness caused increased wear resistance and thus the weight loss was reduced. The microhardness increased with the increase of the ratio of silicon carbide, while, conversely, the density decreased with the increase of the ratio of silicon carbide. The maximum value of hardness was observed for the specimen reinforced with 5% of Sic followed with heat treatment at 284 Hv, while for the specimens reinforced with 4% and 3% Sic it was 255 and 227 Hv, respectively. It can be concluded that when heat treatment and reinforcement by Sic particles are performed, the microhardness value of aluminum 2024 will increase.

Effect of sodium octanoate on the tribocorrosion behaviour of 5052 aluminium alloy

ABSTRACTThe 5000 series aluminium alloys are commonly used in a marine application where it is exposed to environments containing the chloride ions, which cause corrosion of aluminium alloy. The situation becomes even worse when aluminium alloys, in some situations, may suffer from combined corrosion and wear actions. The present study has been carried out to investigate the effect of sodium octanoate as a corrosion inhibitor on the corrosive wear behaviour of aluminium alloy 5052 in 0.5 M NaCl solution as simulated seawater. The effects of electrochemical potentials on the corrosive wear performance are also discussed.

Effect of lubricant additives on the tribological behavior of aluminum alloy against steel

Abstract This study aims to understand the impact of various lubricant additives on the friction- and wear behavior of aluminum alloys against steel. Employing the aluminum alloy Al 6061 and the steel AISI E 52100 as representatives, we studied the effects of the main additives typically found in fully formulated lubricants individually by formulating model lubricants consisting of base oil and just one additive at a time. The additives we studied include sulfurized olefin, complex alkyl phosphate amine, alkyl phosphite, overbased calcium sulphonate, zinc dithiophosphate (ZDP), and calcium sulfonate detergents. For each model lubricant, as well as for the base oil and the fully formulated oil, we performed ball-on-disc experiments with aluminum alloy balls on steel discs. We obtained the friction coefficient, determined the wear volume of the aluminum alloy, and analyzed the composition of the wear surface. We found that all additives except calcium sulfonate detergents promote the formation of aluminum oxide. Among all individually tested additives, zinc dithiophosphate provides the best wear resistance, while sulfurized olefin provides the lowest friction. The lowest friction combined with the second lowest wear rate was actually observed for a fully formulated oil (containing an optimized mixture of several additives).

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The dry sliding wear behaviour of aluminium alloy (LM13) cenosphere syntactic foam with varying cenosphere sizes has been examined at varying applied pressures and sliding speeds. It is interestingly noted that the coefficient of friction, the frictional heating and the wear rate decrease with decrease in cenosphere size. The wear rate and the frictional heating increase with an increase in applied pressure and sliding speed. The coefficient of friction decreases with increase in applied pressure and sliding speed. These have been explained on the basis of the wear surface and wear subsurface examinations. The subsurface examination indicates shearing of cenosphere shells and its alignment along the sliding direction.

Wear Behavior of Aluminum Alloy Reinforced With Beryl Metal Matrix Composites Using Taguchi Method

In the present investigation the dry sliding wear behaviour of aluminium alloys reinforcing with varying in percentage (wt) of beryl particles. wear tests were conducted on samples using pin-on-disc wear testing machine for varying load, sliding distance and Wt % of beryl. The design of experiment approach was employed to acquire data in controlled way using Taguchi technique and variance technique (analysis) were employed to optimize the rate of wear and microstructures of Al-beryl composites. A new mathematical model was obtained to determine the wear rate and microstructure of Al-beryl composites. To confirm the experimental results confirmation tests were conducted

Effect of Repeated Repair Metal Inert Gas Welding on Microstructural Properties, Corrosion Resistance, and Wear Behavior of 5083-H116 Aluminum Alloy

The effect of repeated repair welding, shielded with argon, on microstructural properties, corrosion resistance, and dry sliding wear behavior of aluminum alloy 5083/H116 were investigated. Samples were welded by metal inert gas welding method. 100% argon was used to protect fusion zone. Aluminum alloy 5356 was used as the filler metal. The samples for microstructure, corrosion, and wear tests were prepared from welded and repaired plates. To study the microstructural properties, the samples were mounted, polished, and then etched by the Keller's solution. Optical microscopy was used for metallurgical analysis. The corrosion behavior was evaluated in 3.5% NaCl solution and at a temperature of 25 °C using a potentiodynamic polarization and electrochemical impedance spectroscopy methods. Dry sliding wear behavior was evaluated by pin on disc method and scanning electron microscopy.

Effect of cenosphere size on the dry sliding wear behaviour LM13-cenosphere syntactic foam

The dry sliding wear behaviour of aluminium alloy (LM13) cenosphere syntactic foam with varying cenosphere sizes has been examined at varying applied pressures and sliding speeds. It is interestingly noted that the coefficient of friction, the frictional heating and the wear rate decrease with decrease in cenosphere size. The wear rate and the frictional heating increase with an increase in applied pressure and sliding speed. The coefficient of friction decreases with increase in applied pressure and sliding speed. These have been explained on the basis of the wear surface and wear subsurface examinations. The subsurface examination indicates shearing of cenosphere shells and its alignment along the sliding direction.

Scratch-Induced Wear Behavior of Aluminum Alloy Under Dry and Wet Conditions

Scratch-Induced Wear Behavior of Aluminum Alloy Under Dry and Wet Conditions

Comparison of the mechanical and wear behaviour of aluminium alloy with homogeneous and functionally graded silicon nitride composites

Abstract Homogeneous and functionally graded LM25 aluminium (Al) composites were fabricated by incorporating silicon nitride (10 wt%, 40 µm) particles through liquid metallurgy and centrifugal casting, respectively. The performance of these composites was compared with unreinforced alloy. The microstructural behaviour of the surfaces of unreinforced alloy, homogeneous composite and functionally graded composite (outer, middle and inner surfaces) were examined through optical microscopy. These surfaces were also evaluated for mechanical properties. An abrasive wear test was conducted on all these surfaces to determine their effect on wear rate. The microstructural results revealed a particle-rich region at the outer surface of the functionally graded composite material and uniform dispersion of reinforcement particles in the homogeneous composite. The outer region of the functionally graded composite showed greater hardness and the homogeneous composite displayed higher tensile strength. The abrasive wear rate increased with an increase in load and decreased with an increase in speed, and the particle-rich outer surface showed a lower wear rate. Scanning electron microscopy analysis revealed a particle-rich outer surface of functionally graded composite with fewer scratches. Therefore, higher wear resistance was observed at the outer periphery of functionally graded composites and this property can be well-utilised in automotive tribo-components such as in cylinder liners for improved performance.