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Research Papers: Friction and Wear

High-Temperature Tribology of AA5052/ZrB2 PAMCs

[+] Author and Article Information
Narendra Kumar

Department of Mechanical Engineering,
BIET,
Jhansi 284128, India
e-mail: narendra.dharwan@gmail.com

Gaurav Gautam, Anita Mohan

Department of Physics,
IIT (BHU),
Varanasi 221005, India

Rakesh Kumar Gautam

Department of Mechanical Engineering,
IIT (BHU),
Varanasi 221005, India

Sunil Mohan

Department of Metallurgical Engineering,
Centre of Advanced Study,
IIT (BHU),
Varanasi 221005, India

1Corresponding author.

2Present address: Department of Metallurgical Engineering, Centre of Advanced Study, IIT (BHU), Varanasi 221005, India.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received September 14, 2015; final manuscript received February 10, 2016; published online July 26, 2016. Assoc. Editor: Robert Wood.

J. Tribol 139(1), 011601 (Jul 26, 2016) (12 pages) Paper No: TRIB-15-1335; doi: 10.1115/1.4033097 History: Received September 14, 2015; Revised February 10, 2016

AA5052/ZrB2 particulate aluminum matrix composites (PAMCs) have been produced by in situ reaction of K2ZrF6 and KBF4 compounds with molten alloy at about 860 °C. Dry sliding wear and friction of composites have been investigated for a particular sliding velocity and sliding distance at different loads from ambient temperature to 200 °C. It is revealed that for a particular load and temperature, wear rate and normalized wear rate decrease with increase in the volume percentage of ZrB2 particles whereas coefficient of friction (COF) shows a reverse trend. Wear rate and COF also increase with increase in temperature for a constant load and composition. Whereas with load for a particular temperature, wear rate and wear rate per unit vol. % ZrB2 increase while COF decreases. Worn surface and wear debris morphology examined under scanning electron microscopy (SEM) and profilometer to understand the wear mechanism revealed that wear mode transition takes place from mild-oxidative to severe-metallic at 100 °C for unreinforced alloy, whereas a shifting is observed in transition temperature from 100 to 150 °C for composite with 9 vol. % ZrB2 particles. Energy dispersive spectroscopy (EDS) analysis of worn surface confirms the oxidative wear mode. Profilometry results indicate that wear surface has higher surface roughness at higher values of load and temperatures. Prior to wear and friction studies, composites were also characterized by X-ray diffraction (XRD) and SEM for morphology and microstructural characteristics to correlate with wear results. The findings are very helpful to make the AA5052/ZrB2 composites suitable for the applications, where high-temperature wear is a limiting factor.

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Figures

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Fig. 1

Accessories used during high-temperature wear test

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Fig. 2

XRD pattern of (a) composites and (b) extracted ZrB2 particles

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Fig. 3

SEM micrographs of (a) AA5052-3 vol. % ZrB2, (b) AA5052-6 vol. % ZrB2, (c) AA5052-9 vol. % ZrB2, and (d) morphology of ZrB2 at higher magnification

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Fig. 4

Variation of (a) wear rate, (b) normalized wear rate, and (c) COF with ZrB2 vol. % at different temperatures

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Fig. 5

Worn surface morphology of (a) unreinforced alloy, (b) 3 vol. % ZrB2, (c) 6 vol. % ZrB2, and (d) 9 vol. % ZrB2 composite at RT, 20 N load, and 0.5 m/s sliding velocity

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Fig. 6

Worn surface morphology of (a) unreinforced alloy, (b) 3 vol. % ZrB2, (c) 6 vol. % ZrB2, and (d) 9 vol. % ZrB2 composite at 200 °C temperature, 20 N load, and 0.5 m/s sliding velocity

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Fig. 7

Worn surface morphology of (a) unreinforced alloy and (b) 9 vol. % ZrB2 composite at 200 °C temperature, 20 N load, and 0.5 m/s sliding velocity under profilometer

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Fig. 8

Variation of (a) wear rate and (b) COF with various temperatures for different composites

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Fig. 9

EDS spectrum of worn surface of alloy tested at 50 °C showing oxidative wear mode

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Fig. 10

Worn surface morphology of AA5052-6 vol. % ZrB2 composite at (a) RT, (b) 50 °C, (c) 100 °C, (d) 150 °C, and (e) 200 °C temperature, at 20 N load and 0.5 m/s sliding velocity

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Fig. 11

Wear debris morphology of AA5052-6 vol. % ZrB2 composite at (a) RT and (b) 200 °C

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Fig. 12

Worn surface morphology of AA5052-6 vol. % ZrB2 composite at (a) RT and (b) 200 °C temperature, at 20 N load and 0.5 m/s sliding velocity under profilometer

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Fig. 13

Variation of (a) wear rate, (b) wear rate per unit vol. % ZrB2, and (c) COF with normal loads for different composites

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Fig. 14

Worn surface morphology of AA5052-9 vol. % ZrB2 composite at (a) 10 N, (b) 20 N, (c) 30 N, and (d) 40 N load, at 150 °C and 0.5 m/s sliding velocity

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Fig. 15

Worn surface morphology of AA5052-9 vol. % ZrB2 composite at (a) 10 N and (b) 40 N load, at 150 °C and 0.5 m/s sliding velocity under profilometer

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