Wear Behaviour Of Hybrid Composites Research Articles

Development and characterization of powder metallurgy processed Al/Fe/SiC/MoS2 hybrid composites

This study explores hybrid aluminum matrix composites through powder metallurgy, incorporating silicon carbide, iron, and molybdenum disulfide at varying weight percentages (5%, 10%, and 15%). Defect-free hybrid composites with a uniform distribution of reinforcing particles were fabricated and characterized for microstructure, hardness, density, and wear. The EDX spectra show peaks consistent with Al, Fe, SiC, and MoS2, confirming their presence in developed hybrid composites. The pure aluminum sample presents a relative density higher than that of hybrid composites, while its hardness is lower (25%–41%) than that of hybrid composites. The wear rate decreased with the amount of reinforcing particles. The presence of hard silicon carbide, iron, particles, and lubrication by molybdenum disulfide effectively enhanced the wear behavior of hybrid composites.

Assessment of Wear rate and Coefficient of Friction of Al6262 WC/MoS2 under wet sliding condition

The present paper aims at the results of an experimental examination of hybrid metal matrix composites using stir-casting technique.Aluminum alloy (Al 6062) samples reinforced with Tungsten Carbide (WC) and Molydedneum diSulphide are given. 2wt.% , 4wt.%,6wt.% of MoS2 and 3 wt.%, 6 wt.%, 9 wt.% tungsten carbide were mixed together with the aluminum alloy to create the hybrid composite. The tribological aspects of aluminium composites were studied using Pin on disc Method under wet sliding condition.Testing the hybrid composites' hardness revealed that raising the weight percentage of tungsten carbide might raise the hybrid composites' hardness. To examine the wear behavior of hybrid composites, the Taguchi method was utilized in the design of experiments (DOE) approach. The factors that were found to affect wear rate included load, sliding speed, and reinforcing percentage of WC and MoS2 are the most influencing parameters.

Corrosion Behavior of AZ91/TiC/Al2O3 Hybrid Composites

In the current research, the corrosion behaviors of AZ91 Mg-hybrid composites amalgamated with titanium carbide and alumina reinforcing particles have been investigated. AZ91 Mg-hybrid composites have been developed by using the bottom pouring vacuum-based stir casting process to attain the homogeneous distribution of reinforcing particles in the AZ91-Mg matrix. The corrosion behavior of AZ91-hybrid composites has been evaluated by using corrosion potential (OCP) and potential dynamic polarization scans, as well as friction coefficient, have been deduced to examine the wear behavior of hybrid composites in sodium chloride (3.5%) solution. However, before and after each corrosion and wear test of AZ91-hybrid composites samples, the metallographic structures have been examined by using a scanning microscopic setup. The corrosive results reveal that the corrosion rate of the AZ91-Mg matrix has been greater than AZ91/TiC/Al2O3 composites. The AZ91/TiC/Al2O3 composites result also confirms that the corrosion resistance increases with an increase in wt% of TiC and Alumina. The prime reason for to increase in the corrosion rate is due to the increase in the number of matrix/reinforcement interfaces. However, the friction coefficient and wear rate of AZ91 Mg-hybrid composites rose with the increase in TiC wt%. The type of wear mechanism of AZ91 Mg-hybrid composites has been demonstrated that initially abrasive wear has been observed but later it predominantly transforms to both (i.e., adhesive and abrasive wear) with an increase in TiC wt%.

Gene Expression Programming Model for Tribological Behavior of Novel SiC-ZrO2-Al Hybrid Composites.

In order to improve product format quality and material flexibility, variety of application, and cost-effectiveness, SiC, ZrO2, and Al hybrid composites were manufactured in the research utilizing the powder metallurgy (PM) technique. A model was created to predict the tribological behavior of SiC-ZrO2-Al hybrid composites using statistical data analysis and gene expression programming (GEP) based on artificial intelligence. For the purpose of examining the impact of zirconia concentration, sliding distance, and applied stress on the wear behavior of hybrid composites, a comprehensive factor design of experiments was used. The developed GEP model was sufficiently robust to achieve extremely high accuracy in the prediction of the determine coefficient (R2), the root mean square error (RMSE), and the root relative square error (RRSE). The maximum state of the RMSE was 0.4357 for the GEP-1 (w1) model and the lowest state was 0.7591 for the GEP-4 (w1) model, while the maximum state of the RRSE was 0.4357 for the GEP-1 (w1) model and the minimum state was 0.3115 for the GEP-3 model (w1).

Identification of self-lubricative mode for the ultrasonic treated AA6061-B4C-CNT hybrid composites

This research investigates the self-lubricative behavior of boron carbide (B4C) and carbon nanotube (CNT) reinforced 6061 aluminium alloy hybrid composites. Hybrid composites were prepared by varying the volume percentages (5–15%) of B4C and CNT. Novel ultrasonic vibration (frequency of 20 kHz and power of 2.5 kW) assisted stir casting process was used for fabricating hybrid composites. A pin-on-disc type tribometer mounted with EN-8 as the counterface material was used to evaluate the friction and wear behavior of hybrid composites under dry sliding conditions. Normal loads ranging from 15–45 N and sliding speeds ranging from 1–2 m/s were applied during the experiments. The self-lubricative properties of different hybrid composites were assessed through the examination of the worn surface of pins using surface characterization techniques such as Scanning electron microscopy, Electron dispersive spectroscopy and Raman spectroscopy. The experimental results indicated that the addition of CNT particles increased the hardness of hybrid composites. The matrix strengthening efficiency of CNT was found to be greater at 10 vol.% of B4C, indicating a maximum hardness ranging from 102 to 109 VHN. In comparison, 10 vol.% of CNT hybrid composites showed superior tribological performance at all wear testing conditions. The mode of wear of hybrid composites suggested by the analysis on the worn pin surface was as follows: Scarce (5 vol.% CNT), Tribolayer (10 vol.% CNT) and Fracture (15 vol.% CNT).

Erosion characteristics of epoxy-based Jute, Kenaf and Banana fibre reinforced hybrid composites

In this research work erosion characteristics of bio-based fibres such as jute, kenaf, banana fibre reinforced epoxy hybrid composites were experimentally investigated. Hybrid composites with different stacking sequences of fibres were fabricated by compression moulding method. Erosion wear behavior of hybrid composites were studied using air jet erosion tester as per the ASTM G76 standards. The effect of impingement angle, and exposure duration on the erosion rate of the hybrid composites were analyzed. The results indicated that the erosion rate of hybrid composites increased with the increase in exposure times. Further, maximum erosion rate was observed at 60° of impingement angle for majority of the composite specimens. This proves hybrid composites are semi ductile materials in nature.

Exploring the three body abrasive wear behavior of glass – Carbon thermoplastic hybrid composites

The interaction effect of abrasive particles on three body abrasion wear behavior of Glass – Carbon thermoplastic hybrid composites was investigated. The blend (PA66/PTFE) (80/20 wt%), Blend/Short glass fiber (SGF), Blend/Short Carbon fiber (SCF), Blend/10 wt% SGF/10 wt% SCF (GC) were the material systems considered for the study. The melt mix method with the help twin screw extruder and injection molding were the methods used for processing and development of hybrid composites. The experimentation was conducted for 20 N and 30 N using varying distance at a constant velocity of 2.5 m/s in accordance with ASTM G65 method. The unique observation has been made from the fiber filled composites. The three body abrasion wear behavior has been effectively improved due to fiber reinforcement. The individual fibers have their own contribution in developing the abrasion resistance. The hardness and ultimate tensile strength of the composites have supported the wear resistance. Further, the Ratner – Lancaster factor (σε) of composites played the significant role in enhancing the wear behavior under three body mode. SCF filled composites exhibited better wear behavior than SGF filled ones. The hybridization effect of both SGF and SCF effectively improved the abrasion wear resistance of GC hybrid composites. The high crystallanity, hardness and hardness ratio between polymer and rubber wheel helped in improving the abrasion wear behavior of hybrid composites. The morphology of the abraded surfaces were studied using SEM images.

Studies on mechanical property and wear behaviour of AA7075 hybrid composites prepared by a conventional casting method

The research article addresses the reciprocating wear behaviour of hybrid AA7075 reinforced with boron carbide and boron nitride through a stir-casting technique. The experiment involved varying wt.% of the secondary particle boron carbide (3, 6 and 9) while boron nitride (3) was kept as constant. The hybrid composites were characterised using scanning electron microscopy coupled with energy dispersive spectroscopy. The hardness and tensile behaviour of the hybrid composites were evaluated. Reciprocating wear behaviour of the hybrid composites were examined using a tribometer by varying the wear parameters such as load and sliding distance. The results revealed that AA7075/6boron carbide/3boron nitride had better hardness, tensile and wear properties. The surface morphology of the wear samples was analysed using SEM.

Experimental investigation on effect of RE oxides addition on tribological and mechanical properties of Al-6063 based hybrid composites

In the present investigation, wear behaviour of hybrid composites based on aluminum alloy (Al-6063 series) with SiC and RE (Rare Earth) mixture CeO2 and La2O3 as reinforcement was examined. For this purpose, the hybrid composite samples were fabricated using stir casting route by varying weight percentages of 1, 2, 3 wt% of RE (CeO2 + La2O3) mixture and 3, 6, 9 wt% of SiC powder. Dispersion of the reinforced particles was studied with x-ray diffraction, electron back scattered diffraction and scanning electron microscopy analyses. Mechanical properties such as micro-hardness, ultimate tensile strength and percentage elongation of the prepared hybrid composites samples were measured at room temperature. The results revealed that a certain amount of rare earth content (2 wt%) could enhance the ultimate tensile strength, micro-hardness and percentage elongation of the Al-6063 aluminium alloy. At the end, the sliding wear tests were performed on hybrid composites with highest value of hardness and base alloy. The load range was varied from 10 to 30N, whereas sliding velocity from 0.5 to 2 m s−1. It is observed that 2 wt% RE alloy composite reinforced with 6 wt% of SiC exhibits 89.40% improvement in wear rate as compared to the base alloy. It is also observed that the composite without RE and reinforced with 6 wt% of SiC exhibits only 42% of improvement in wear rate as compared to base alloy. The reason of improvement in the wear rate was found due to the formation of the Al11RE3 intermetallic phase. Abrasion, oxidation and delamination were identified as prevailing wear mechanism at a load of 10N with 0.5 m s−1 sliding velocity. At the load of 20 N and 30N with 1 m s−1 and 2 m s−1 sliding velocities, the hybrid composite surface experienced delamination and plastic deformation wear.

Analysis of tribological behaviour of zirconia reinforced Al-SiC hybrid composites using statistical and artificial neural network technique

The tribological performance of aluminium hybrid composites reinforced with micro SiC (5 wt%) and nano zirconia (0, 3, 6 and 9 wt%) fabricated through powder metallurgy technique were investigated using statistical and artificial neural network (ANN) approach. The influence of zirconia reinforcement, sliding distance and applied load were analyzed with test based on full factorial design of experiments. Analysis of variance (ANOVA) was used to evaluate the percentage contribution of each process parameters on wear loss. ANOVA approach suggested that wear loss be mainly influenced by sliding distance followed by zirconia reinforcement and applied load. Further, a feed forward back propagation neural network was applied on input/output date for predicting and analyzing the wear behaviour of fabricated composite. A very close correlation between experimental and ANN output were achieved by implementing the model. Finally, ANN model was effectively used to find the influence of various control factors on wear behaviour of hybrid composites.

Effect of Reinforced SiC Particulates of Different Grit Size on Mechanical and Tribological Properties of Hybrid Polymer Matrix Composites

In today’s world, advancement in materials is attaining new heights due to scientifically enriched mechanical, chemical and physical properties. Among these advance materials, fiber reinforced polymer composites offers a number of eye-catching properties like enhanced strength to weight ratio, wear and electrical resistance as compared to counterpart materials. These properties attract manufactures to incorporate these materials for components which are subjected to multiple impacts and high wear losses. As per need of hour, this paper deals with assessment of hybrid polymer matrix composites (PMCs) for various output quality characteristics using silicon carbide (SiC) as a secondary reinforcement. The experiments were designed for tribological behavior of hybrid composites as per Taguchi’s methodology using suitable orthogonal array. The results were analyzed qualitatively as well as quantitatively. The result predicts that mechanical and tribological properties of hybrid composite were significantly affected by grit size and weight fraction of reinforcing SiC particles. The increase in tensile strength of composite up to 20% can be attained by increasing weight fraction whereas increase in grit size of secondary reinforcement minifies tensile strength by 12%. The analysis of variance for wear test provides the significance of process parameters influencing tribological behavior of hybrid composite. Worn out surfaces of hybrid composites was analyzed using scanning electron microscopy which illustrated wear behavior of hybrid composites.

Optimization of Wear Behavior of Magnesium Alloy AZ91 Hybrid Composites Using Taguchi Experimental Design

In the present paper, the statistical investigation on wear behavior of magnesium alloy (AZ91) hybrid metal matrix composites using Taguchi technique has been reported. The composites were reinforced with SiC and graphite particles of average size 37 μm. The specimens were processed by stir casting route. Dry sliding wear of the hybrid composites were tested on a pin-on-disk tribometer under dry conditions at different normal loads (20, 40, and 60 N), sliding speeds (1.047, 1.57, and 2.09 m/s), and composition (1, 2, and 3 wt pct of each of SiC and graphite). The design of experiments approach using Taguchi technique was employed to statistically analyze the wear behavior of hybrid composites. Signal-to-noise ratio and analysis of variance were used to investigate the influence of the parameters on the wear rate.

Optimization of Tribological Performance of Al-6061T6-15% SiCp-15% Al<sub>2</sub>O<sub>3</sub> Hybrid Metal Matrix Composites Using Taguchi Method & Grey Relational Analysis

In this investigation, optimization of tribological performance parameters of Al-6061T6 alloy reinforced with SiC (15% by weight) and Al2O3 (15% by weight) particulates having particle size of 37 μm each has been presented. The wear and frictional properties of the hybrid metal matrix composites have been studied by performing dry sliding wear test using pin-on-disc wear tester. A L27 orthogonal array is selected for the analysis of the data. From the test results it is observed that sliding distance has the significant contribution in controlling the friction and wear behaviour of hybrid composites. A confirmation test is also carried out to verify the accuracy of the results obtained through the optimization. In addition an optical micrograph test is also performed on the wear tracks to study the wear mechanism.

Investigation of organo-modified montmorillonite loading effect on the abrasion resistance of hybrid composites

The carbon fabric reinforced epoxy (C–E) with different loading of organo-modified montmorillonite (oMMT) hybrid composites were prepared using hand lay-up technique followed by autoclave curing. The effects of oMMT loading on mechanical properties and three-body abrasive wear behaviour of hybrid composites have been investigated. The three-body abrasive wear tests with different loads/abrading distances were performed at room temperature using a Rubber wheel abrasion test apparatus. Experimental results obtained from tensile tests indicate that the tensile strength and modulus of hybrid composites increases with the increment of oMMT nanoparticles. Furthermore, the C–E specimens with 5wt% oMMT loading exhibit superior tensile strength than those that do not contain any oMMT nanoparticles. The abrasive wear test results showed that the wear volume increased with increasing abrading distance and the specific wear rate decreased with increasing abrading distance/load for all hybrid composites. Among the oMMT loaded hybrid composite samples tested, 5wt% oMMT loaded hybrid composite showed a promising trend. Free volume property of the hybrid composites measured from positron lifetime spectroscopy seems to correlate well with the mechanical and wear properties. Finally, the different wear mechanisms were observed on the worn surface of the hybrid composites including micro and macro cracks, pitting, as well as debonding and breakage of the fibers by scanning electron microscopy, atomic force microscopy coupled with vision measure scope.

Modelling and analysis of erosion wear behaviour of hybrid composites using Taguchi experimental design

This article describes the development of multi-phase hybrid composites consisting of polyester reinforced with E-glass fibre and ceramic particulates. It further investigates the erosion wear response of these composites and presents a comparison on the influence of two different particulate fillers cement by-pass dust (CBPD) and alumina (Al2O3) on the wear characteristics of glass-polyester composites. For this purpose, the erosion test schedule in an air jet-type test rig is made following design of experiment approach using Taguchi's orthogonal arrays. Taguchi approach enables one to determine optimal parameter settings that lead to minimization of erosion rate. The results indicate that erodent size, filler content, impingement angle, and impact velocity influence the wear rate significantly. This study reveals that addition of hard particulate fillers like CBPD and Al2O3 improves the erosion resistance of glass-polyester composites significantly. An industrial waste like CBPD exhibits reasonably good filler characteristics. Finally, a popular evolutionary approach known as genetic algorithm is used to generalize the method of finding out optimal factor settings for minimum wear rate.

Study on mechanical and erosion wear behavior of hybrid composites using Taguchi experimental design

This paper describes the development of multi-phase hybrid composites consisting of polyester reinforced with E-glass fiber and ceramic particulates. It further investigates the erosion wear response of these composites and presents a comparison on the influence of three different particulate fillers cement by-pass dust (CBPD), alumina (Al 2O 3) and silicon carbide (SiC) on the wear characteristics of glass–polyester composites. For this purpose, the erosion test schedule in an air jet type test rig is made following design of experiments approach using Taguchi’s orthogonal arrays. Taguchi approach enables to determine optimal parameter settings that lead to minimization of erosion rate. The results indicate that erodent size, filler content, impingement angle and impact velocity influence the wear rate significantly. The experimental results are in good agreement with the values from the theoretical model. An artificial neural network (ANN) approach is also applied to predict the wear rate of the composites and compared with the theoretical results. This study reveals that addition of hard particulate fillers like CBPD, Al 2O 3 and SiC improves the erosion resistance of glass–polyester composites significantly. An industrial waste like CBPD exhibits better filler characteristics compared to those of alumina and SiC. Finally, a popular evolutionary approach known as genetic algorithm (GA) is used to generalize the method of finding out optimal factor settings for minimum wear rate.

Effect of volume fraction of carbon fibers on wear behavior of Al/Al 2O 3/C hybrid metal matrix composites

Wear behavior of Al/Al 2O 3/C hybrid metal matrix composites fabricated by squeeze casting method was characterized. The effects of volume fraction of carbon fiber on wear behavior of hybrid composites was investigated. Wear behavior of Al/Al 2O 3/C composites was characterized by the dry spindle wear test under various sliding speeds. The wear resistance of Al/Al 2O 3/C composites was remarkably improved over Al/Al 2O 3 composites by adding carbon fibers to Al/Al 2O 3/C composites. Specifically, at the intermediate sliding speed the wear resistance of Al/Al 2O 3/C composites containing 8 vol.% carbon fiber was found to be better than that of the rest of the carbon hybrid composites. From fractographic studies, damaged sections in wear surfaces of hybrid composites at intermediate sliding speed were not observed due to the formation of solid lubrication film. The solid lubrication film which was formed as a result of adding carbon fibers improved the wear resistance of carbon hybrid composites because this film reduced the high friction force between MMCs and counter material.