Experimental Investigation on Two-Body Abrasion of Cast Aluminum–Alumina Composites: Influence of Abrasive Size and Reinforcement Content

2019 ◽  
Vol 142 (3) ◽  
Author(s):  
Santanu Sardar ◽  
Santanu Kumar Karmakar ◽  
Debdulal Das
Keyword(s):  
Stir Casting ◽  
Matrix Composites ◽  
Cast Aluminum ◽  
Alloy Matrix ◽  
Test Configuration ◽  
Alumina Composites ◽  
Al Matrix Composites ◽  
Three Body Abrasion ◽  
Three Body ◽  
Abrasive Size

Abstract The occurrence of abrasion is inevitable in most engineering systems. Abrasive wear specifically two-body causes higher material and dimensional loss than other modes of wear. Two-body abrasion is yet to be fully comprehended as it is governed by several intrinsic and extrinsic variables. In this article, tribo-performances of Al-composites were experimentally studied with specific emphasis on the role of abrasive size and amount of reinforcement. AA7075 alloy matrix composites with different amounts of alumina particles were fabricated by the advanced stir-casting method. Besides measurements of density, porosity, and Vickers hardness, in-depth characterizations of microstructures were performed. Specific wear-rate (SWR), coefficient of friction (COF), and abraded surface roughness (SR) of developed materials were measured under two-body abrasion over a vast range of distance, load, velocity, and abrasive size. Under all abrasion conditions, composites exhibited higher SR but lower SWR and COF over alloy; the differences increased with reinforcement quantity. SWR, COF, and SR rose with an increase in abrasive size; however, only SR varied with sliding distance for any material. The effects of different variables on the recorded tribo-performances were explained through identification of various micro-mechanisms of abrasion via extensive post wear characterizations and microstructural features. Finally, the criteria for the occurrence of three-body abrasion even in two-body test configuration were highlighted. The wear coefficient value of 10 × 10−3 was identified as the demarcation between two-body and two-body plus three-body abrasion for Al-matrix composites.

Production of Al Metal Matrix Composites by the Stir-Casting Method

2013 ◽  
Vol 592-593 ◽  
pp. 614-617 ◽  
Author(s):  
Konstantinos Anthymidis ◽  
Kostas David ◽  
Pavlos Agrianidis ◽  
Afroditi Trakali
Keyword(s):  
Mechanical Properties ◽  
Metal Matrix Composites ◽  
Automobile Industry ◽  
Metal Matrix ◽  
Aluminum Matrix ◽  
Stir Casting ◽  
Aluminum Matrix Composites ◽  
Matrix Composites ◽  
Casting Method ◽  
Alloy Matrix

It is well known that the addition of ceramic phases in an alloy e.g. aluminum, in form of fibers or particles influences its mechanical properties. This leads to a new generation of materials, which are called metal matrix composites (MMCs). They have found a lot of application during the last twenty-five years due to their low density, high strength and toughness, good fatigue and wear resistance. Aluminum matrix composites reinforced by ceramic particles are well known for their good thermophysical and mechanical properties. As a result, during the last years, there has been a considerable interest in using aluminum metal matrix composites in the automobile industry. Automobile industry use aluminum alloy matrix composites reinforced with SiC or Al2O3 particles for the production of pistons, brake rotors, calipers and liners. However, no reference could be cited in the international literature concerning aluminum reinforced with TiB particles and Fe and Cr, although these composites are very promising for improving the mechanical properties of this metal without significantly alter its corrosion behavior. Several processing techniques have been developed for the production of reinforced aluminum alloys. This paper is concerned with the study of TiB, Fe and Cr reinforced aluminum produced by the stir-casting method.

Regression Modeling and Experimental Investigations on Ageing Behavior of Nano-Fly Ash Reinforced Al-10wt%Mg Alloy Matrix Composites

2018 ◽  
Vol 6 (2) ◽  
pp. 36-49
Author(s):  
Srinivasa Prasad Katrenipadu ◽  
Swami Naidu Gurugubelli
Keyword(s):  
Fly Ash ◽  
Regression Model ◽  
Weight Fraction ◽  
Stir Casting ◽  
Mg Alloy ◽  
Peak Hardness ◽  
Experimental Investigations ◽  
Matrix Composites ◽  
Casting Method ◽  
Alloy Matrix

Nano-fly ash particles reinforced Al-10wt%Mg alloy matrix composites produced by stir-casting method were tested for their ageing response. Ageing studies were performed at 160 °C, 200 °C and 240 °C temperatures and a maximum peak hardness of 142 VHN was observed during ageing at 200 °C for the composite with 10 wt% nano fly ash reinforcement. This is due to rapid nucleation and growth of βI particles at this temperature. Experiments were designed for different compositions and different ageing temperatures on the basis of the Design of Experiments technique. The factorial design is considered to improve the reliability of results and to reduce the size of experimentation without loss of accuracy. A model to predict the ageing behaviour of the composites was developed with the terms of 5, 10 and 15% weight fraction of fly ash at 160 °C, 200 °C and 240 °C ageing temperatures. The developed regression model was validated by statistical software MINITAB-R17.1.0. It was found that the developed regression model could be effectively used to predict the ageing behavior at 95% confidence level.

Studies on Dry Sliding Wear Characteristics of Ceramic Al2O3 Particulate Reinforced 6061Al Matrix Composites

2014 ◽  
Vol 984-985 ◽  
pp. 319-325 ◽  
Author(s):  
V. Bharath ◽  
Madeva Nagaral ◽  
V. Auradi ◽  
S.A. Kori
Keyword(s):  
Sliding Wear ◽  
Testing Machine ◽  
Stir Casting ◽  
Wear Testing ◽  
Dry Sliding Wear ◽  
Dry Sliding ◽  
Matrix Composites ◽  
Wear Properties ◽  
Alloy Matrix ◽  
Particulate Reinforced

In the current investigation an attempt has been made and to produce ceramic Al2O3particulate reinforced 6061Al matrix composites by liquid metallurgy route (stir casting technique) and to study the dry sliding wear properties of the prepared composites. The amount of ceramic Al2O3particulate reinforcement addition was maintained at 9 and 12wt%. During the preparation of each composite the ceramic reinforcements were introduced in a novel way which involves three stage additions of reinforcements during melt stirring. The wear tests were conducted using pin on disc wear testing machine on 6061Al matrix before and after addition of Al2O3reinforcements Wear test results demonstrated the superior wear resistance of the composites over monolithic 6061Al alloy matrix. Key Words: MMC’s, Al2O3particulates, 6061Al, stir-casting

An Investigation of Material Removal Mechanisms in Lapping with Grain Size Transition

2000 ◽  
Vol 122 (3) ◽  
pp. 413-419 ◽  
Author(s):  
Y. P. Chang ◽  
M. Hashimura ◽  
D. A. Dornfeld
Keyword(s):  
Material Removal ◽  
Model Verification ◽  
Time Dependent ◽  
Depth Of Cut ◽  
Statistical Nature ◽  
Material Removal Mechanisms ◽  
Effective Inclusion ◽  
Three Body Abrasion ◽  
Three Body ◽  
Abrasive Size

The mechanical material removal (MRR) mechanisms in lapping were investigated, using concepts of two-body vs. three-body abrasion and ductile vs. brittle machining. The statistical nature of the depth of cut in the lapping process was described using distribution of abrasive sizes in the slurry. Through the change in abrasive size distribution, the time dependent characteristic of MRR was captured in the model. Experiments were conducted for model verification. It was found that a constant 60 deg effective inclusion angle allowed the model to fit measurement well. [S1087-1357(00)00504-9]

Flank Wear Progression During Machining Metal Matrix Composites

2005 ◽  
Vol 128 (3) ◽  
pp. 787-791 ◽  
Author(s):  
S. Kannan ◽  
H. A. Kishawy ◽  
M. Balazinski
Keyword(s):  
Tool Wear ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Flank Wear ◽  
Tool Geometry ◽  
Matrix Composites ◽  
Proposed Model ◽  
Three Body Abrasion ◽  
Three Body ◽  
Bar Turning

The machining of composites present a significant challenge to the industry. The abrasive reinforcements cause rapid tool wear and increases the machining cost. The results from machining metal matrix composites (MMCs) with conventional tools show that the main mechanism of tool wear includes two-body abrasion and three-body abrasion. A more flexible method that can be considered as a cost-saving technique is therefore sought for studying the machinability characteristics of these materials. In the previous paper, a methodology for predicting the tool flank wear progression during bar turning of MMCs was presented (Kishawy, Kannan, and Balazinski, Ann. CIRP, 54/1, pp. 55–59). In the proposed model, the wear volume due to two-body and three-body abrasion mechanisms was formulated. Then, the flank wear rate was quantified by considering the tool geometry in three-dimensional (3D) turning. Our main objective in this paper is to validate the proposed model by conducting extensive bar turning experiments under a wide range of cutting conditions, tool geometries, and composite material compositions. The cutting test results showed good agreement between predicted and measured tool wear progression.

Friction and Wear Behaviour of Al2O3 Particulates Reinforced Al-Mn Alloy Matrix Composites

2010 ◽  
Vol 150-151 ◽  
pp. 1000-1004 ◽  
Author(s):  
Xin Mei Li ◽  
Bing Liu ◽  
Wen Lei Sun ◽  
Xiang Liu
Keyword(s):  
Aqueous Solution ◽  
Friction And Wear ◽  
Brinell Hardness ◽  
Stir Casting ◽  
Wear Behaviour ◽  
Matrix Composites ◽  
Alloy Matrix ◽  
Friction Coefficients ◽  
Hardness Tester ◽  
Mass Losses

Al-2%Mn alloy matrix composites reinforced with Al2O3 particulates was fabricated by stir-casting, and the hardness and friction and wear behaviour of the composites were analyzed using Brinell hardness tester and ring-on-block tribometer under both dry and lubricated sliding in which the .SO4•Cl- Na•Ca• Mg corrosive alkalescent aqueous solution accompanied with SiO2 and Al2O3 grinding particles was used as lubricant. The wear mechanism and the effect of Al2O3 particulates on the friction and wear behaviour of the composites were discussed. The results showed that the friction coefficients of the samples under dry condition are generally lower than those under lubricated one. In comparison with the base aluminium and the Al-2%Mn alloy, the hardness of the composites increases~70%, the friction coefficients are lower in most cases especially at higher applied loads under lubricated condition, and the wear mass losses are much less at any applied loads whether under dry or lubricated condition. The composites possesses a good wear-resistance and antifriction due to its higher hardness.

scholarly journals Impact on Mechanical Properties of Hybrid Aluminum Metal Matrix Composites

2019 ◽  
Vol 8 (6) ◽  
pp. 1638-1645 ◽  
Keyword(s):  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Hybrid Composites ◽  
Base Alloy ◽  
Mechanical Tests ◽  
Matrix Composites ◽  
Cast Aluminum ◽  
Alloy Matrix ◽  
Aluminum Metal ◽  
Aluminum Metal Matrix Composites

Hybrid composites are those composites which have a combination of two or more reinforcements in a single matrix. In this study, Hybrid Aluminum Metal Matrix Composites were fabricated by using Stir Casting technique. Hybrid composites with three reinforcements such as Aluminum oxide(Al2O3 ), Silicon Carbide (SiC) and Boron Carbide (B4C) in different proportions are considered and Aluminum alloy 6061-T6 (Al6061) as base alloy matrix. Later, the cast aluminum metal matrix composites were machined as per ASTM standards with required dimensions. Mechanical tests such as tensile, flexural, Charpy impact, Brinell Hardness tests were conducted on the composites fabricated inorder to evaluate effect of reinforcements. Morphological study of the composites is carried out by using Scanning electron microscope (SEM). The test results were studied and analyzed.

scholarly journals A simple stir casting technique for the preparation of in situ Fe-aluminides reinforced Al-matrix composites

2016 ◽  
Vol 8 ◽  
pp. 529-532 ◽  
Author(s):  
Susanta K. Pradhan ◽  
Subhranshu Chatterjee ◽  
Amitava Basu Mallick ◽  
Debdulal Das
Keyword(s):  
Stir Casting ◽  
Matrix Composites ◽  
Casting Technique ◽  
Al Matrix Composites ◽  
Al Matrix

Friction and Wear Performance of Ti-Al Matrix Composites under 650°C

2014 ◽  
Vol 1004-1005 ◽  
pp. 501-504
Author(s):  
Xiu Ling Wang ◽  
Li Ying Yang ◽  
Shou Ren Wang ◽  
Yi Zhang ◽  
Hang Hai Yu
Keyword(s):  
High Temperature ◽  
Friction And Wear ◽  
Al Alloy ◽  
Matrix Composites ◽  
Alloy Matrix ◽  
Wear Performance ◽  
Al Matrix Composites ◽  
Hot Pressing Sintering ◽  
Al Matrix ◽  
Self Lubricating Composites

Ti-Al alloy matrix self-lubricating composites were fabricated by the method of high temperature hot pressing sintering. The friction and wear performance of self-lubricating Ti-Al matrix composites were studied at high temperature. The study found that the friction coefficient decreased with the increase of solid lubricant, CaF2 and BaF2 had played good lubrication. when the lubricant BaF2-CaF2 mass fraction was 10%, the wear rate of composites to the lowest, it was 0.29×10−7cm3N-1m-1in 650°C high temperature.

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