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Research Papers: Friction and Wear

Wear and Friction of AA5052-Al3Zr In Situ Composites Synthesized by Direct Melt Reaction

[+] Author and Article Information
Gaurav Gautam

Department of Physics,
Indian Institute of Technology (BHU),
Varanasi, Uttar Pradesh 221005, India
e-mail: gauravgautamm1988@gmail.com

Anita Mohan

Department of Physics,
Indian Institute of Technology (BHU),
Varanasi, Uttar Pradesh 221005, India
e-mail: amohan.app@iitbhu.ac.in

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received April 9, 2015; final manuscript received August 3, 2015; published online October 15, 2015. Assoc. Editor: Dae-Eun Kim.

J. Tribol 138(2), 021602 (Oct 15, 2015) (12 pages) Paper No: TRIB-15-1111; doi: 10.1115/1.4031401 History: Received April 09, 2015; Revised August 03, 2015

Particulate aluminum matrix composites (PAMCs) with different volume percent of Al3Zr particles have been developed by direct melt reaction (DMR). Wear and friction have been studied in detail for all compositions under dry sliding conditions. Results indicate that the wear rate, normalized wear rate, and wear coefficient of PAMCs decrease continuously with increase in volume percent of Al3Zr particles, however, with applied load and sliding distance, wear continuously increases. Wear rate and wear coefficient with sliding velocity initially decrease for all compositions, attains minima, and then increase sharply. However, coefficient of friction shows increasing trend with composition and sliding velocity but with load it shows a decreasing trend and with distance slid it fluctuates within a value of ±0.025. At low load and sliding velocity three-dimensional (3D)-profilometer, scanning electron microscope (SEM), and debris studies show low Ra values and mild wear dominated by oxidative nature, whereas at high loads and sliding velocities high Ra values and wear nature change to severe wear with mixed mode (oxidative–metallic) and surface with deep grooves is observed. Further, it is also important to note from morphological studies that refinement of matrix phase takes place with in situ formation of Al3Zr particles, which helps to improve hardness and tensile properties finally contributing to low wear rate.

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Figures

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Fig. 1

XRD pattern of AA5052/Al3Zr PAMCs with different volume percent of Al3Zr: (a) base alloy, (b) 10, (c) 12.5, and (d) 15

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Fig. 2

Optical microstructures of (a) as-cast AA5052 alloy and (b) PAMC with 10 vol. % Al3Zr

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Fig. 3

SEM micrograph showing (a) distribution of Al3Zr particles, (b) rectangular particle, and (c) polyhedron particle

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Fig. 4

Particle size histogram of Al3Zr particles in PAMC

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Fig. 5

Fractrographs of (a) AA5052 Al alloy; (b) PAMC with 10 vol. % Al3Zr, and (c) Al3Zr particles within dimples at higher magnification

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Fig. 6

(a) Variation of cumulative weight loss with sliding distance and (b) coefficient of friction with sliding distance

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Fig. 7

(a) Variation of wear rate with normal load, (b) wear rate/volume percentage Al3Zr with normal load, and (c) coefficient of friction with normal load

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Fig. 8

(a) Variation of wear rate with sliding velocity, (b) wear coefficient with sliding velocity, and (c) coefficient of friction with sliding velocity

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Fig. 9

(a) Variation of wear rate with volume percentage of Al3Zr, (b) normalized wear rate with volume percentage of Al3Zr, (c) wear coefficient with volume percentage of Al3Zr, and (d) coefficient of friction with volume percentage of Al3Zr

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Fig. 10

Line analysis and its 3D-profilometry images for AA5052/10 volume percentage Al3Zr PAMC before wear test

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Fig. 11

SEM micrographs of wear tracks of PAMC with 15 vol. % Al3Zr at different loads: (a) mild-oxidative wear at 10 N, (b) severe-oxidative–metallic wear at 40 N, and (c) large and deep cracks in surface at higher magnification for (b)

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Fig. 12

Line analysis perpendicular to wear track and its 3D-profilometer images for PAMC with 10 vol. % Al3Zr composite at 1 m/s sliding velocity and load: (a) 30 N and (b) 40 N

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Fig. 13

SEM micrographs and corresponding EDS pattern of the worn surfaces for composite at 20 N normal load with different sliding velocities: (a) 2 m/s and (b) 4 m/s

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Fig. 14

Line analysis perpendicular to wear track and its 3D-profilometer images for PAMC with 10 vol. % Al3Zr at different sliding velocities of (a) 2 m/s and (b) 4 m/s

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Fig. 15

Broken oxide layer with uneven surface of wear tracks for different volume percentages of Al3Zr at 40 N load: (a) 0, (b) 10, (c) 12.5, and (d) 15

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Fig. 16

Line analysis perpendicular to wear track and its 3D-profilometer image at 1 m/s sliding velocity and 20 N load for (a) AA5052 alloy and (b) PAMC with 10 vol. % Al3Zr

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