Dry Sliding Wear Investigation of Al6082 GR Metal 2016 Journal of Materials
Dry Sliding Wear Investigation of Al6082 GR Metal 2016 Journal of Materials
2 0 1 6;5(1):29–36
www.jmrt.com.br
Original Article
a r t i c l e i n f o a b s t r a c t
Article history: The effect of graphite particles on the dry sliding wear behaviour of Al6082 alloy compos-
Received 2 December 2014 ites produced by conventional stir casting method has been investigated. The percentage
Accepted 5 May 2015 of reinforcement was varied from 0% to 12% in a step of 3. The result showed that with the
Available online 10 June 2015 addition of graphite particles micro- and macro-hardness reduced by 11.11% and 10.44%,
respectively. The tribological behaviour of composites was investigated by pin on disc appa-
Keywords: ratus. Percentage reinforcement, load, sliding speed and sliding distance were taken as the
Metal matrix composites (MMCs) process variable. Response surface methodology has been used to plan and analyze the
Dry sliding wear experiment. Results showed that sliding distance is the most influential factor and load is
Stir casting the factor which affects the wear least.
Graphite (Gr) © 2015 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier
Aluminium matrix composites Editora Ltda. All rights reserved.
(AMCs)
Aluminium (Al)
∗
Corresponding author.
E-mail addresses: [email protected] (P. Sharma), [email protected] (D. Khanduja), [email protected]
(S. Sharma).
http://dx.doi.org/10.1016/j.jmrt.2015.05.001
2238-7854/© 2015 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier Editora Ltda. All rights reserved.
30 j m a t e r r e s t e c h n o l . 2 0 1 6;5(1):29–36
Content % 97.14 0.038 0.690 1.16 0.258 0.04 0.580 0.027 <0.001 0.006 0.048 0.042 <0.01
compared to unreinforced alloy have better properties such 1.2. Selection of metal matrix
as high strength, high stiffness, high wear resistance and
high thermal stability, furthermore these properties can be Aluminium 6082 is a medium strength alloy with excellent
adapted to a specific requirement [4]. Graphite is a soft rein- corrosion resistance and manganese present in it controls the
forcement which prevents metal to metal contact by forming grain structure, which results into a stronger alloy and its
a thin layer of Gr particle because of its self-lubricating prop- application are in the field of high stress application, bridges,
erties, so Al–Gr composites have better wear resistance than trusses, cranes, transport application, etc. Amount of silicon in
conventional aluminium alloy. Liu et al. [5] observed a linear 6082 is high, which increases its wear resistance and copper is
relationship between wear volume and load for Al–Gr com- low so it is highly wear and corrosion resistant. The properties
posites manufactured by laser processed method and revealed of AA6082 can be further improved if it is alloyed properly with
that Gr particles formed a thin lubricating film, which signif- reinforcement like Gr to enhance its wear resistance so that
icantly improved the wear resistance of composites. Lin et al. the developed composites can be used in tribological applica-
[6] observed for Al–Gr composite when Gr particles increased tions where wear resistance is of main concern.
from 0% to 6% wear has been reduced, this may be due to
graphite formed a thin lubricating film which prevented direct 1.3. Aim of research
contact of sliding surfaces and reduced ploughing effects of
Al chips. Hassan et al. [7] manufactured the Al–Gr compos- A limited research work or almost nil has been reported on
ite and reported decrease in hardness with increase in % wear behaviour of Gr reinforced composites by taking Al6082
reinforcement of Gr due to increased porosity. Akhlaghi and metal matrix containing wide range of reinforcements. In this
Bidaki [8] fabricated Al2024 composites with varying amount research the dry sliding wear behaviour of AA6082/Gr compos-
of Gr (5–20%) by in situ powder metallurgy process and found ite (by varying Gr particles range from 0% to 12% by weight)
that an increase in Gr content reduced the coefficient of fric- produced in an inert atmosphere using conventional stir cast-
tion, hardness and fracture toughness of composites. Ted ing are presented.
and Tsao [9] concluded that the addition of Gr resulted in
reduced wear of Al–Gr composites compared to Al alloy. Jha
et al. [10] reported that wear rate of AA6061–Gr composites 2. Research methodology
increased with increasing the amount of graphite reinforce-
ment by powder metallurgy process. Liu et al. [11] reported 2.1. Development of composite by stir casting process
that both the wear and friction of Al2014–Gr composites man-
ufactured by squeeze casting decreased when the volume The proposed Al6082/Gr composites required for the analy-
fraction of graphite reached upto 50%. Rohatgi et al. [12] sis are fabricated by stir casting. AA6082-T6 is used as the
reported that aluminium matrix composites reinforced with matrix alloy and details of its composition after spectro-Lab
hard particles like SiC showed higher wear and coefficient of test is given in Table 1. Table 2 provides the details of Gr par-
friction than soft particles like Gr. Baradeswaran and Peru- ticulates, which are used as reinforcement. A batch of 1000 g
mal [13] concluded that AA7075/Gr composites manufactured of aluminium alloy was measured and put in the graphite
by liquid casting technique had better wear resistance than crucible and was melted at 900 ◦ C using an electric furnace.
pure aluminium matrix and wear resistance increased with To obtain homogeneous distribution of reinforcement in the
increased amount of Gr whereas hardness and tensile strength melt proper stirring is required. The melt was stirred with
decreased. the help of a mechanical stirrer to form a fine vortex for
10 min [17,18]. The Gr ceramic powder was preheated to a
1.1. Selection of fabrication method temperature of 500 ◦ C so that their surface oxidized, this pre-
heated ceramic powder was added at a constant feed rate into
There are a number of manufacturing methods available to vortex. Argon gas was supplied into the melt during opera-
fabricate AMCs like powder metallurgy, ball milling, friction tion to provide an inert atmosphere. After stirring the molten
stir processing, pressure-less infiltration method, etc., but mixture, it was poured into the mould of dimension 12 mm
conventional stir casting is an attractive and economical pro- diameter and 55 mm length. Argon gas was supplied until the
cess and can produce complex shape products and offers a
wide range of material and processing condition [14–16]. It
offers better matrix particles bonding due to stirring action of
particles into the melts. As a cost effective process stir casting Table 2 – Details of Reinforcement.
can be used in mass production of composite manufacturing Reinforcement Hardness Grain size Density
at industrial scale. Owing to all these advantages, stir cast- (GPa) (m) (g/cm3 )
ing is employed in present research for the development of
Gr 0.25 50 2.2
composites.
j m a t e r r e s t e c h n o l . 2 0 1 6;5(1):29–36 31
−2 −1 0 +1 +2
Reinforcement (%) R 0 3 6 9 12
Load (N) L 15 30 45 60 75
Sliding speed (m/s) S 0.4 0.8 1.2 1.6 2.0
Sliding distance (m) D 400 800 1200 1600 2000
Microhardness (VHN)
46.5
solidification. The AMCs having different weight percentage 48
40
The micro-hardness of composites was measured using Vick-
ers hardness tester (MITUTOYO-MVK-H1) at a load of 500 g 38
applied for a duration of 15 s at 20 different locations on all 0 3 6 9 12
% Wt of graphite addition
specimens.
Fig. 1 – Variation of micro-hardness with weight
2.3. Macro-hardness measurement percentage of Gr addition.
Table 4 – Design matrix and various factors with their actual and coded value (in parentheses).
Run no. Process parameters Wear (g)
Reinforcement (R) Load (L) Sliding speed (S) Sliding distance (D)
in-turns results into decrease in hardness with increase in where Y is the response (yield), f is the response function, ε is
weight percentage of Gr particles. These results are in line with the experimentation error, and X1 , X2 , X3 , . . ., Xn are indepen-
previous investigations [7,8,13]. dent input process parameters.
Expected response Y is plotted with the help of input pro-
3.2. Development of wear model by RSM cess parameter to obtain a response surface. The response
function ‘f’, which is not known to us, is very complicated
In RSM the input process parameters are represented in the to determine. RSM is used for this purpose, the main aim of
form of response in the quantitative form as: which is to approximate f by determining a range of inde-
pendent input process parameters by applying a lower order
polynomial equation. If the model is appropriate and suitable
Y = f (X1 , X2 , X3 , . . ., Xn ) ± ε (1)
then the response of the model can be represented by a linear
function in terms of independent process parameters, then
the response represented in Eq. (1) can be written as
33
31.6
31
32
30.2 Y = C0 + C1 X1 + C2 X2 + . . .Cn Xn ± ε (2)
Macrohardness (BHN)
31
26
n
n
Y = C0 + Ci Xn + di Xi2 ± ε (3)
25
i=1 i=1
0 3 6 9 12
% Wt of graphite addition
The central composite design (CCD) was used in this
Fig. 2 – Variation of macro-hardness with weight experimental study. Significance testing of the coefficients,
percentage of Gr addition. adequacy of the model and analysis of variance was carried
j m a t e r r e s t e c h n o l . 2 0 1 6;5(1):29–36 33
% Reinforcement (R) Load (L) Sliding speed (C) Sliding distance (D) Exp. Predicted Error (%)
of wear with an increase of percentage reinforcement Fig. 3(a). in Fig. 3(b)–(d). The coefficient associated with load, sliding
This is attributed due to the presence of Gr particles, which as speed and sliding distance is 1.033 × 10−4 , 1.883 × 10−3 and
a soft lubricant formed a layer between the sliding surfaces 4.542 × 10−3 , respectively. This signifies that sliding distance
and prevented the contact of sliding surfaces [6]. The effect has a more detrimental effect than the applied load and slid-
of load, sliding speed and sliding distance on wear is shown ing speed on the wear of the composite. The effect of load on
0.0199
a 0.0199 b
0.015075 0.015075
Wear (g)
Wear (g)
0.01025 0.01025
0.005425 0.005425
0.0006 0.0006
3.00 4.50 6.00 7.50 9.00 30.00 37.50 45.00 52.50 60.00
Reinforcement, R (%) Load, L (N)
0.0199 c 0.0199 d
0.015075 0.015075
Wear (g)
Wear (g)
0.01025 0.01025
0.005425 0.005425
0.0006 0.0006
0.80 1.00 1.20 1.40 1.60 800.00 1000.00 1200.00 1400.00 1600.00
Fig. 3 – Effect of individual factors on dry sliding wear (a) percentage reinforcement, (b) load, (c) sliding speed, and (d) sliding
distance.
j m a t e r r e s t e c h n o l . 2 0 1 6;5(1):29–36 35
0.00372917
percentage of Gr.
2. The wear rate of composites decreased with increasing
sliding speed and percentage reinforcement and increased
1600.00
60.00 with increasing load, sliding distance.
1400.00
52.50 3. The wear resistance of developed composites was lower
1200.00
45.00 than that of cast AA6082 at all combination of reinforce-
D: Sliding distance, D (m) 1000.00 37.50
800.00 30.00
B: Load, L (N) ment, load, sliding speed and sliding distance.
4. ANOVA indicated that sliding distance is the most
Fig. 4 – Effect of load and sliding distance interaction on influential factor followed by sliding speed, percentage
wear. reinforcement and load on the wear rate of composites.
5. The interaction between load (L) and sliding distance (D)
also has significant effect on the wear rate of composites.
6. The confirmation experiments showed that the error
wear is shown in Fig. 3(b) the wear increased with increase in
between experimental and predicted value of wear rate lies
load, which is due to the fact that with increase in load con-
within range 3–10%.
tact pressure increased on the sliding surfaces which resulted
into increased wear at high load. The effect of sliding speed
on the wear is shown in Fig. 3(c) where low as compared to
sliding distance. The wear decreased with increased in sliding Conflicts of interest
speed, which may be due to the fact that higher sliding speeds
results in increase in temperature. This increase in tempera- The authors declare no conflicts of interest.
ture further leads to oxidation of the contact surfaces. The
hard nature of oxides results in low wear of the composite.
Also at higher sliding speed the time of interaction between
references
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material removed. The effect of sliding distance on the wear
is shown in Fig. 3(d) where the wear increased with increase
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