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Research Papers: Tribochemistry and Tribofilms

Effect of Ceramic and Metallic Reinforcement on Mechanical, Corrosion, and Tribological Behavior of Aluminum Composite by Adopting Design of Experiment Through Taguchi Technique

[+] Author and Article Information
P. Sureshkumar

Department of Mechanical Engineering,
Ramco Institute of Technology,
Rajapalayam 626117, Tamil Nadu, India
e-mail: sureshkumar@ritrjpm.ac.in

V. C. Uvaraja

Department of Mechanical Engineering,
Bannari Amman Institute of Technology,
Sathyamangalam 638401, Tamil Nadu, India
e-mail: c_uva@rediffmail.com

1Corresponding author.

Contributed by the Tribology Division of ASME for publication in the JOURNAL OF TRIBOLOGY. Manuscript received August 26, 2017; final manuscript received February 21, 2018; published online April 10, 2018. Assoc. Editor: Dae-Eun Kim.

J. Tribol 140(5), 052301 (Apr 10, 2018) (12 pages) Paper No: TRIB-17-1334; doi: 10.1115/1.4039527 History: Received August 26, 2017; Revised February 21, 2018

An attempt has been made to develop and study the properties and behavior of structure-based aluminum composite. Aluminum (AA6063)-based composites were fabricated by stir casting technique (also known as liquid metallurgy route) by varying weight percentage of metallic-based copper nitrate Cu (NO3)2 with fixed proposition of ceramic-based silicon nitride (Si3N4) reinforcement. The mechanical and corrosion properties and tribological behavior of composite were studied. Further, the sample microstructure and characterizations were investigated by scanning electron microscope (SEM) and X-ray diffraction (XRD) technique. The composite with fixed weight proportion of ceramic and higher metallic reinforced samples shows higher tensile strength, improved corrosion resistance, and higher hardness behavior. Due to higher hardness nature, the tribological properties of composite such as wear rate and coefficient of friction have been reduced. Moreover, the impact strength of composite decreased due to combination of ceramic and metallic reinforcement. In addition to the above study, design of experiment (DOE) was adopted to optimize the major wear test parameters such as percentage of reinforcement, applied load, sliding distance, and sliding speed. Finally, analysis of variance (ANOVA) was carried out to identify the most significant test parameter and its interaction affecting wear behavior and its coefficient of friction of composite sample.

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Figures

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Fig. 1

Stir casting furnace setup

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Fig. 2

SEM image (a) AA6063/12Si3N4 with 0% copper nitrate, (b) AA6063/12Si3N4 with 2% copper nitrate, and (c) AA6063/12Si3N4 with 4% copper nitrate

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Fig. 3

XRD pattern of AA6063, copper nitrate, and composite

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Fig. 4

Tensile testing specimen sample

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Fig. 5

Pin-on-disk tribometer: (a) pin-on-disk setup, schematic representation of pin-on-disk and (b) specimen holder and rotating disk

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Fig. 6

Variation of macro hardness with varying weight percentage of Cu(NO3)2

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Fig. 7

Variation of tensile strength with weight percentage of Cu(NO3)2

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Fig. 8

Stress–strain for varying weight percentage of Cu(NO3)2

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Fig. 9

Fractography image of composite sample

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Fig. 10

Variation of impact strength with varying weight percentage of Cu(NO3)2

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Fig. 11

(a) Weight loss versus varying weight percentage of Cu (NO3)2 and (b) corrosion rate versus varying weight percentage of Cu (NO3)2

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Fig. 12

SEM of wear debris at higher magnification after wear test

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Fig. 13

(a) Main effect of plot for S/N ratio—wear rate and (b) main effect of plot for S/N ratio—coefficient of friction

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Fig. 14

(a) Interaction plot for S/N ratio—wear rate and (b) interaction plot for S/N ratio–coefficient of friction

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