Al–Zn–Mg–Cu matrix composites reinforced with (0–20 wt %) Al2O3 particles have been manufactured by enhanced stir casting technique. Microstructural characterization of cast composites by optical, field emission scanning electron microscope (FESEM), energy dispersive X-ray (EDS) and X-ray diffraction (XRD) reveals homogeneous distribution of reinforcements in Al-alloy matrix with MgZn2 plus Al2CuMg intermetallics. With increasing particle content, hardness of composite rises considerably in spite of marginal rise in porosity. Tribological performance under two-body abrasion has been studied considering central composite design (CCD) apart from identification of mechanisms of wear via characterizations of abraded surfaces and debris. Composites exhibit significantly reduced wear rate and coefficient of friction (COF) irrespective of test conditions, since mechanisms of abrasion are observed to change from microplowing and microcutting in unreinforced alloy to mainly delamination with limited microplowing in composites. Effects of four independent factors (reinforcement content, load, abrasive grit size, and sliding distance) on wear behavior have been evaluated using response surface-based analysis of variance (ANOVA) technique. Dominant factors on both wear rate and COF are identified as reinforcement content followed by grit size and load. Combined optimization of wear rate and COF employing multiresponse optimization technique with desirability approach as well as regression models of individual responses have been developed, and their adequacies are validated by confirmatory tests. The developed mathematical models provide further insight on the complex interactions among wear performances of the selected materials and variables of abrasive system. The optimum amount of reinforcement is identified at around 15 wt % for achieving the lowest values of both wear rate and COF.
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April 2019
Research-Article
Microstructure and Tribological Performance of Alumina–Aluminum Matrix Composites Manufactured by Enhanced Stir Casting Method
Santanu Sardar,
Santanu Sardar
Department of Mechanical Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Search for other works by this author on:
Santanu Kumar Karmakar,
Santanu Kumar Karmakar
Department of Mechanical Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
e-mails: skk@mech.iiests.ac.in;
skk.besus@gmail.com
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
e-mails: skk@mech.iiests.ac.in;
skk.besus@gmail.com
Search for other works by this author on:
Debdulal Das
Debdulal Das
Department of Metallurgy and
Materials Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Materials Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Search for other works by this author on:
Santanu Sardar
Department of Mechanical Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Santanu Kumar Karmakar
Department of Mechanical Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
e-mails: skk@mech.iiests.ac.in;
skk.besus@gmail.com
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
e-mails: skk@mech.iiests.ac.in;
skk.besus@gmail.com
Debdulal Das
Department of Metallurgy and
Materials Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
Materials Engineering,
Indian Institute of Engineering
Science and Technology,
Shibpur,
Howrah 711103, West Bengal, India
1Corresponding author.
Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received June 13, 2018; final manuscript received November 24, 2018; published online January 16, 2019. Assoc. Editor: Yi Zhu.
J. Tribol. Apr 2019, 141(4): 041602 (22 pages)
Published Online: January 16, 2019
Article history
Received:
June 13, 2018
Revised:
November 24, 2018
Citation
Sardar, S., Karmakar, S. K., and Das, D. (January 16, 2019). "Microstructure and Tribological Performance of Alumina–Aluminum Matrix Composites Manufactured by Enhanced Stir Casting Method." ASME. J. Tribol. April 2019; 141(4): 041602. https://doi.org/10.1115/1.4042198
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