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Research Article | Open Access

Identification and modelling of applicable wear conditions for stir cast Al-composite

Santanu SARDAR1, Santanu Kumar KARMAKAR1, Debdulal DAS2( )
Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Howrah 711103, India
Department of Metallurgy and Materials Engineering, Indian Institute of Engineering Science and Technology, Howrah 711103, India
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Abstract

A comprehensive study of the tribological performance of the Al-Zn-Mg-Cu/Al2O3 composite and its matrix alloy is presented in this paper, with a specific emphasis to identify and model the applicable wear conditions where the composite provides a minimum of 50% reduction in wear rate and 25% lowering of the friction coefficient. Two-body abrasion experiments following Taguchi L27 orthogonal design have been performed separately on alloy and composite materials, both prepared by the stir casting method. The influence of crucial control factors including silicon carbide (SiC) abrasive size, load, sliding distance, and velocity on the percentage variations of wear rates and friction coefficients between alloy and composite have been studied using the analysis of variance technique and full quadratic regression method. The dominant control factors are identified as abrasive size, load, and the interaction between abrasive size and load. This has been verified by establishing the influence of abrasive size and load on variations of wear mechanisms like microcutting, microploughing, and delamination, identified by means of in-depth characterization of worn surfaces and generated debris for both alloy and composite. The selection of applicable tribological condition for the composite has been accomplished by adopting the multi-response optimization technique based on combined desirability approach to obtain concurrent optimization of the percentage variations of wear rates and friction coefficients. Predictive models correlating the superiority of tribological performance of composite with abrasion conditions have been developed, and these are found to be accurate (errors <10%), as determined by confirmatory experiment.

Keywords

aluminum matrix compositetribologydesign of experimentTaguchimulti-response optimizationabrasion mechanism

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Friction
Volume 8 Issue 5,
October 2020
Pages 847-873
DOI: 10.1007/s40544-019-0302-6
Cite this article:
SARDAR S, KARMAKAR SK, DAS D. Identification and modelling of applicable wear conditions for stir cast Al-composite. Friction, 2020, 8(5): 847-873. https://doi.org/10.1007/s40544-019-0302-6

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Received: 07 July 2018
Revised: 08 February 2019
Accepted: 11 May 2019
Published: 02 October 2019
© The author(s) 2019

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