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Research Papers: Friction & Wear

Wear Characterization of Al/Ingredients MMFC

[+] Author and Article Information
Anil K. Chaturvedi

Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Roorkee, Roorkee 247667, Indiacvedi_anil@rediffmail.com

K. Chandra, P. S. Mishra

Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Roorkee, Roorkee 247667, India

J. Tribol 131(4), 041601 (Sep 22, 2009) (7 pages) doi:10.1115/1.3195041 History: Received September 02, 2008; Revised July 01, 2009; Published September 22, 2009

In this study, dry sliding wear behavior of Al alloy (Al 2219) based metal matrix friction composites (AlMMFCs) incorporated with varying percentage of ingredients: silicon carbide particles (1525wt%SiCp) and solid lubricants with 4wt% graphite and 1wt% antimony trisulphide (Sb2S3) were investigated. A group of four new chemical formulations, three binary composites of Al/SiCp (Al01N, Al02N, and Al03N), and a hybrid composite of Al/SiCp/solid lubricants (Al04N) were fabricated by newly a developed “cold-hot powder die compaction” method. Physical and mechanical properties were measured as usual. To measure tribological properties, dry pin-on-disk wear tests were conducted for 1 hour at varying loads of 1 MPa and 2 MPa and at sliding speeds of 3 m/s, 5 m/s, 7 m/s, and 9 m/s. The results revealed that the incorporation of SiCp from 15wt% to 25wt% in binary composite, density (2.8–2.9 g/cc), apparent porosity (1.43.4vol%), and hardness (78–93 BHN) were increased. For hybrid composite, density (2.9–2.76 g/cc) and hardness (93–81 BHN) were decreased with the increase in apparent porosity (3.44.1vol%). It was concluded that the obtained density is higher than the reported density and the obtained apparent porosity is much lower than the reported apparent porosity by Aigbodi (2007, “Effects of Silicon Carbide Reinforcement on Microstructure and Properties of Cast Al–Si–Fe/Sic Particulate Composites,” Mater. Sci. Eng., A, 447, pp. 355–360) for same composition using “double stir casting” method. The value of coefficient of friction with addition of solid lubricants increased and steady at high load and speed (2 MPa, >5m/s).The microstructures, worn surfaces, and tribolayers are also analyzed by an optical microscope and SEM. This study overviews AlMMFCs incorporated with hard particles and solid lubricants and the new technology for producing brake lining parts from these novel materials.

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Copyright © 2009 by American Society of Mechanical Engineers
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Figures

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Figure 1

(a) Disk worn surface over wear test at 2 MPa, 9 m/s and (b) test pin

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Figure 2

Effects of wt % of ingredients on hardness, density, and porosity

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Figure 3

Effect of speeds on wear rate with varying ingredients

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Figure 4

Effect of speeds on coefficient of friction with varying ingredients

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Figure 5

Effect of speed on wear rate of varying percentages of SiC

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Figure 6

Effect of speed on coefficient of friction of varying percentages of SiCp

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Figure 7

(a) Variation in coefficient of friction with sliding time and ingredient at 1 MPa and (b) variation in coefficient of friction with sliding time and ingredient at 2 MPa

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Figure 8

Optical micrographs of microstructure of test pins before wear test: (a) Al01N, (b) Al02N, (c) Al03N, and (d) Al04N

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Figure 9

SEM micrographs of worn surfaces of test pins over wear test at load of 2 MPa and speed of 9 m/s: (a) Al01N, (b) Al02N, (c) Al03N, and (d) Al04N

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