Advances in Materials and Processing Technologies

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Tribological characteristics of Al6061, boron, and

graphite hybrid metal matrix composites

Nagesh D, Raghavendra S, NM Sivaram, Suresh S, Manjunatha B & Sanketh S

To cite this article: Nagesh D, Raghavendra S, NM Sivaram, Suresh S, Manjunatha B

& Sanketh S (2021): Tribological characteristics of Al6061, boron, and graphite hybrid
metal matrix composites, Advances in Materials and Processing Technologies, DOI:
10.1080/2374068X.2021.1946323

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ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES
https://doi.org/10.1080/2374068X.2021.1946323

RESEARCH ARTICLE

Tribological characteristics of Al6061, boron, and graphite

hybrid metal matrix composites
Nagesh Da, Raghavendra Sb, NM Sivaramc, Suresh Sd, Manjunatha Be and Sanketh Sf
a
Department of Mechanical Engineering, S.J.C.I.T, Chickballapur, India; bDepartment of Mechanical
Engineering, Sai Vidya Institute of Technology, Bangalore, India; cDepartment of Mechanical Engineering,
National Institute of Technology, Karaikal, Puducherry, India; dSchool of Mechanical Engineering, Reva
University, Bangalore, India; eDepartment of Mechanical Engineering, Acharya Institute of Technology,
Bangalore, India; fDepartmentof Mechanical Engineering, Dayananda Sagar College of Engineering,
Bangalore, India

ABSTRACT ARTICLE HISTORY

Tribological properties of any substance give an overview of the life Accepted 18 June 2021
of the substance with respect to its application. Here an attempt is
KEYWORDS
made to investigate the effect of parameters of wear test equip­ Boron; graphite; aluminium
ment considering the material type on the wear rate of different composite; stir casting; wear
composition of hybrid MMC considered. Al6061 is considered as the rate; analysis of variance
base matrix and Boron 2 wt% and Graphite 2 wt% are considered as
the reinforcement to develop the hybrid MMC with the traditional
technique of stir casting. As the work deals with optimisation
process the design of experiments is done through Taguchi tech­
nique considering L27 orthogonal array with the varying para­
meters (input) as material (combination of Al-B, Al-Gr and Al-B-Gr),
load and speed, to analyse the effects on wear rate as the response.
A wear test was performed using pin-on disk apparatus at room
temperature for constant load of 20 N, 30 N, 40 N at a fixed sliding
speed of 400,600,800 RPM and wear rate increased as the weight
percentage of reinforcement increased. The major contribution
along with the ranks of the parameters was found out using the
Analysis of Variance, from which it is clear that, Boron is the sig­
nificant factor that affects the hardness and wear loss of hybrid
composites followed by Graphite. Confirmatory test was performed
for the optimised parameters and the results were within the
acceptable range when compared with the experimental results.

1. Introduction
Metal–matrix composites are materials in which tailored properties are achieved by
systematic combinations of various constituents [1]. Aluminium is the most popular
matrix for the metal matrix composites (MMCs). The Al alloys are quite attractive due to
their low density, their capability to be strengthened by precipitation, their good corro­
sion resistance, high thermal and electrical conductivity, and their high damping capa­
city. Aluminium matrix composites (AMCs) have been widely studied since the 1920s
and are now used in sporting goods, electronic packaging, armours, and automotive

CONTACT Raghavendra S [email protected] Dept of Mechanical Engineering, Sai Vidya Institute of

Technology, Bangalore, India
© 2021 Informa UK Limited, trading as Taylor & Francis Group
2 N. D ET AL.

industries [2]. They offer a large variety of mechanical properties depending on the
chemical composition of the Al-matrix. The term ‘composite’ broadly refers to a material
system which is composed of a discrete constituent (the reinforcement) distributed in
a continuous phase (the matrix), and which derives its distinguishing characteristics from
the properties of its constituents, from the geometry and architecture of the constituents,
and from the properties of the boundaries (interfaces) between different constituents.
Composite materials are usually classified on the basis of the physical or chemical nature
of the matrix phase, e.g. polymer matrix, metal-matrix and ceramic composites [3–6].
There is a considerable demand for lightweight, high specific strength and environmen­
tally friendly materials in domestic, automotive and aerospace industries [7].
Aluminium MMCs offer a superiorly significant arrangement of qualities or combina­
tion of qualities in a way that no other conventional material can match. Aluminium
MMCs have been evaluated and used in a variety of structural, nonstructural, and
purposeful applications in many engineering fields in the past. Presentation, profitability,
and environmental benefits are the main reasons for the use of Aluminium MMCs in
various domains.
Composites with graphite-reinforced aluminium metal matrix that have low friction,
low wear rate, and excellent antiseizing properties. The graphite in these composites is
thought to improve tribological properties by forming a graphite-rich film on the tribo-
surface, which provides solid lubrication.
Because of its layered structure and solid lubricative property, carbon has a wide range
of applications in the manufacture of components requiring high wear resistance, such as
engine bearings, pistons, piston rings, and cylinder liners [8].
Ceramic particles such as SiC, B4C, Al2O3, and TiC have been successfully used to
improve the tribological properties of MMCs. B4C are a good mix of qualities among
these reinforcements. B4C is a nice mixture of qualities among these reinforcements.
After diamond and cubic boron nitride, it is the third hardest substance. Figure 1 shows
the Image of Al6061,Graphite and Boron.
It has a density of 2.52 g/cm3, which is similar to aluminium. It is a good contender for
imparting wear resistance to the composite due of its higher hardness. It has a melting

Figure 1. Al-6061, graphite and boron.

 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 3

point of 2445°C, which helps to improve the thermal properties of the composite, such as
temperature resistance. It is resistant to a wide range of chemicals [9,10].
Graphite is the most well solid lubricant with the added benefit of low density.
Graphite serves as a solid lubricating layer between the composite and the rubbing
surface in graphite reinforced Aluminium Matrix Composites, minimising composite
wear without the need of standard solid and liquid lubricants [11]. In particular, it was
revealed that the composites without graphite had higher wear susceptibility than the
composite grades that contained graphite for all composite series created. By providing
a firm lubricating layer between the composite and the rubbing hard counter surface,
graphite is said to assist lower the wear rate of composites [12]. Conversely, as the
graphite concentration was increased from 0.5 to 1.5 wt percent, the wear resistance
dropped.
The demand is increasing for the advanced aluminium metal matrix composites
because, as compared to other metals aluminium is abundantly available and cost of
production is lesser and simple as compared to other composite materials.
Therefore, in this study, different amounts of boron and graphite were added to
Aluminium matrix, and the composite materials were produced by mechanical stir
casting method. It is aimed to determine the effect of addition of boron in different
amounts in the structure of composite materials on the microstructure and wear beha­
viours under a constant load.
With this background, the objectives of the present study include (i) preparation of Al
6061-B4C-graphite Hybrid composites having 2 wt. % each B4C and Graphite particles
and (ii) their characterisation in respect of their mechanical and wear behaviour. Also,
attempt has been made (i) to understand the significance of quantity of reinforcement on
wear loss of MMCs and (ii) analysis of variance method (ANOVAs) of boron carbide
reinforced Aluminium metal composites and their significance on wear loss

2. Material and experimentation

Alloy 6061 is one of the most widely used alloys in the 6000 series. This standard
structural alloy is one of the most versatile of the heat-treatable alloys and is popular
for medium- to high-strength requirements having good toughness characteristics. Al-
6061 has excellent corrosion resistance to atmospheric conditions and good corrosion
resistance to seawater. This alloy also offers good finishing characteristics and responds
well to anodising; however, where cosmetic appearance is critical, consider the use of
alloy 6061 is considered [13]. The most common anodising methods include clear, clear
and colour dye, and hard coat. Alloy 6061 is easily welded and joined by various
commercial methods.
A typical chemical composition of Al 6061 is presented in Table 1. Its superior
corrosion resistance makes it a suitable candidate material for marine structural applica­
tions. The demand for lighter weight, cost-effective, and high-performance materials for

Table 1. Chemical composition of Al 6061.

Elements Cr Cu Mg Zn Fe Mn Si Ti Al
Actual value % 0.35 0.40 1.20 0.25 0.70 0.15 0.80 0.15 95.85
4 N. D ET AL.

use in a spectrum of structural and non-structural applications has resulted in the need
for fabrication of metal matrix composites (MMCs) of various types [14]. In recent years,
the aluminium alloy-based MMCs have offered designers many added benefits particu­
larly suited for applications requiring good strength at high temperatures, due to good
structural rigidity, dimensional stability, light weight and low thermal expansion. The
major advantages of Aluminium Matrix composites (AMCs) include greater strength,
improved stiffness, reduced density, improved high temperature properties, controlled
thermal expansion coefficient, thermal/heat management, enhanced and tailored elec­
trical performance, improved abrasion and wear resistance, and improved damping
capabilities.
The chemical composition of the Al-6061 after the above treatments is given in
Table 1.

2.1. Reinforcement material

Reinforcement is commonly a high strength material, which is reinforced into the matrix
that carries the load acting on it. The materials that are used as reinforcements may have
much more strength, resist chemical corrosion, resist or conduct electricity, stiffness, etc.
The primary function of reinforcements is to take up the loads. The reinforcements used
in this project work are graphite and boron.
Graphite is mainly used as reinforcement with aluminium matrix in order to improve
its strength and stiffness. The particles of graphite can easily combine with aluminium
matrix and it gives an identical property throughout the composite material.
In making Al-6061, boron and graphite metal matrix composits, Al-6061 is used as
base alloy as it is very light weight. Graphite is used to avoid wear in the components and
boron is added to give good hardness to the material. All these metals together contribute
to the improved properties of the composite.

2.2. Preparation of composites

Al6061 alloy is melted in a ceramic crucible in a electrical furnace shown in Figure 2A.
The temperature of the molten metal is raised to 720°C and after complete melting and
degassing of the aluminium alloy by nitrogen, stirring is carried out. The particles of
boron and graphite are preheated to 600°C with a view to removing gases and to avoid
a temperature drop during casting. Equal proportions of these preheated particles are
introduced into the molten metal for preparing the first set of three specimens and
poured into the mould (Figure 2B) [15,16].
The micro structural images of aluminium metal matrix composites have clearly
indicated fewer amounts of defects and identical distribution of the particulate
reinforcements.

2.3. Micro structural examination

The study of microstructure helps in analysing the distribution of distinct particles in
the Al-6061 metal matrix phase. The microstructure was observed using optical micro­
scope. For each composition, three samples at different places of the cast specimen
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 5

Figure 2. (a). Electrical resistance furnace. (b) Pouring liquid metal into metal mould.

were taken and subjected to micro structural analysis and the observations made were
recorded.
From Figures 3 and 3.2 it is clear that, the distribution of reinforcing particulates in
both the composites is fairly uniform in all the compositions studied, when the % of
reinforcements increased the grain boundaries arrangement also decreased because of
the increased in mechanical defects. The size of the graphite particles appears to be
uniform (Figure 3.2) throughout the aluminium matrix. Metallographic examination
reveals that the presence of reinforcement particles were observed on the matrix phase as
dark spots, The number of dark spots areas increased in the matrix phases as the addition
of particles increased.
Mechanical properties of the Aluminium Metal Matrix Composites (AMMCs) are
investigated using Vickers Hardness Test Rig for hardness (VHTR), Pin on Disc Machine
(PDM) for tribological behaviour.
The present work is focused on preparation of a metal matrix composite com­
prising an alloy Al-6061 which is the matrix material of the composite, with
a particulate mixture of boron and graphite serving as the reinforcements. The
above combination of matrix and reinforcement materials are selected for the
present work as this combination facilitates in developing a low density, high
strength, and structurally rigid MMC. In particular the significance of inclusion of
boron in particulate form is its lightness than the aluminium (Figure 3). Further the
addition of boron with graphite served as a solid lubricant since it is a soft, slippery
and greyish-black substance. Because of the crystal loose interlamellar coupling,
graphite has good lubricating properties and increases the strength and stability of
the MMC.
Figure 3 shows the EDS result to support the presence of graphite and boron
particles in aluminium matrix. Al-6061 is used as base matrix and boron and
graphite as reinforcement materials for development of MMCs. For different com­
positions of Al- 6061, boron and graphite particulates were made according to their
weight ratio by stir casting technique.
6 N. D ET AL.

Figure 3. (Fig 3.1) Microstructure of Al-6061, (Fig 3.2) Al-6061 + 2% Graphite, (Fig 3.3) Al-6061 + 2%
Boron, (Fig 3.4) electron diffraction spectroscopy of Al-6061, Graphite Boron Sample.

2.4. Specimen preparation

The dimensions of the specimen prepared are as per ASTM standards.
Microstructure of a material was observed using microscopy techniques. The micro­
structural features vary immensely when observed at different length scales. So, it is
important to consider length scale of observations during describing the micro­
structure of a material. The specimens that are used for microstructure test were
used for the determination of density after the completion of microstructure test.
The specimens that are used for the microstructure and density tests were used for
the Vickers Hardness test after the completion of the microstructure test and
density test. The wear test specimens were prepared by turning process in
a conventional lathe according to ASTM G99 standards. The above experimentation
procedure was repeated for different weight fractions of Al-6061 boron and graphite
metal matrix composites.
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 7

3. Results and discussions

3.1. Density results
The density test was conducted by water displacement method for different compositions
of the composites and the base metal. The density of the composites decreased slightly
due to addition of 2% graphite and 2% boron.
The density of the base metal (Al-6061) is very near to its theoretical value (2.7 g/cc)
shown in Figure 4. The density of stir casting is less than that of the base metal. The
density of stir casting of Al-6061, boron and graphite metal matrix composites is nearer
to the density of the base metal.

3.2. Mechanical properties

3.2.1. Hardness
The micro hardness tests were carried out according to ASTM standards using Vickers
Hardness tester with a 10 mm diamond indenter and the load of 1 kg for a period of
10 seconds is applied on specimens. The hardness was measured at three different
locations on the sample to get an average hardness value. The specimen prepared as
per ASTM standards were subjected to Micro Vickers Hardness test, and the results
obtained are tabulated 68.7 ± 1.0, 77. ±1.0, 68. ±1.0and 71.0 ± 1.0 (Figure 5).

3.2.2. Wear test

Dry sliding wear tests were conducted using pin on disk wear testing (at room tempera­
ture) apparatus under the varying speed and varying load with hardened D2 steel disk
The specimen was cut from the cast samples as per ASTM standard (ASTM G99). Wear
rate is a volume loss per unit distance expressed in mm3/m. It is independent of load

2.71
2.7
2.69
Density gm/cc

2.68
2.67
2.66
2.65
2.64
Al6061 Al6061-2% Al6061-2% Boron Al6061+2%
Graphite Graphite+ 2%
Boron
Composition
Figure 4. Graph of density v/s weight percentage of different material compositions.
8 N. D ET AL.

90
80
Vicker Hardness (HV) 70
60
50
40
30
20
10
0
Al6061 Al6061-2% Al6061-2% Boron Al6061+2%
Graphite Graphite+ 2%
Boron
Composition
Figure 5. Graph of Vicker hardness v/s % weight of different material compositions.

2.50E-04
400rpm
Wear rate (mm 3/m)

2.00E-04 600rpm
800rpm
1.50E-04

1.00E-04

5.00E-05

0.00E+00
20 30 40
Load (N)
Figure 6. Load v/s wear rate of Al-6061 + 2% Graphite for various speeds.

applied. Following Figures 6–8 shows Load v/s wear rate of Al-6061 + 2%Graphite, Al-
6061 + 2% Boron, Al-6061 + 2% Boron +2% Graphite for various speed.

3.3. Optimisation of wear parameters

The Design of Experiments (DOE) approach is used to employ the analysis of hardness
and wear properties. According to the Taguchi method, L27 orthogonal array are
conducted for reducing the number of experiments. The parameters considered for the
present study are wt. % of reinforcements as shown in Table 2.The purpose of the
optimisation is to validate the optimum levels of parameters. The mathematical models
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 9

3.00E-04
400rpm
2.50E-04 600rpm
800rpm

Wear rate(mm 3/m)

2.00E-04

1.50E-04

1.00E-04

5.00E-05

0.00E+00
20 30 40

Load (N)

Figure 7. Load v/s wear rate of Al-6061 + 2% boron for various speeds.

6.00E-04
800rpm
5.00E-04 600rpm
Wear rate(mm 3/m)

4.00E-04 400rpm

3.00E-04

2.00E-04

1.00E-04

0.00E+00
20 30 40
Load (N)

Figure 8. Load v/s wear rate of Al-6061 + 2% Graphite+2% Boron for various speeds.

are used to predict the hardness and wear loss which is formulated by response surface
regression analysis. The suitability and significance of developed regression model were
tested using predictable regression coefficient technique [17]. The influences of wear loss
are discussed with the help of following ANOVA results.
The adequacy and significance of the regression model was tested using Analysis of
Variance (ANOVA) method. ANOVA was carried out on the results obtained at a level of
significance of 5% with a p-value less than 0.05 being significant and a confidence level of 95
%. The significance of the factors was confirmed by the main effects plot. The ANOVA
analysis results for wear are of hybrid metal matrix composite shown in Table 3. The results
indicated that Load is highest significance on wear rate followed by speed and wt% of
ceramic particles. The main effects plots of mean and S/N ratio for the hybrid composites
10 N. D ET AL.

Figure 9. Main effect plot for wear rate.

Figure 10. Main effect plot SN ratios for wear rate.

are shown in Figures 9–11 respectively. The wear rate increased with increase in load and
sliding speed. As the sliding speed increased at the interface between pin and disc, friction
induced temperature increased.
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 11

Figure 11. Interaction plot for wear rate.

Table 2. Experimental results of wear rate for L27 Orthogonal Array.

Wt% Load (N) Speed (rpm) Wear Rate (mm3/m) SNRA1
1 20 400 0.0000007 123.571
1 20 600 0.0000297 90.559
1 20 800 0.0000061 104.296
1 30 400 0.0000068 103.315
1 30 600 0.0001732 75.23
1 30 800 0.0001445 76.804
1 40 400 0.000194 74.246
1 40 600 0.0001511 76.413
1 40 800 0.0000852 81.39
2 20 400 0.0000008 121.988
2 20 600 0.0000026 111.676
2 20 800 0.0001574 76.062
2 30 400 0.0000076 102.357
2 30 600 0.0001486 76.561
2 30 800 0.0001358 77.343
2 40 400 0.0002547 71.878
2 40 600 0.0001637 75.717
2 40 800 0.0001153 78.763
3 20 400 0.0000111 99.065
3 20 600 0.0000291 90.729
3 20 800 0.0000081 101.809
3 30 400 0.0000083 101.633
3 30 600 0.0001722 75.279
3 30 800 0.0001545 76.222
3 40 400 0.000018 94.912
3 40 600 0.0002773 71.139
3 40 800 0.0001082 79.317
12 N. D ET AL.

Table 3. Analysis of variance (ANOVA) for wear rate.

Source DF Seq SS Adj SS Adj MS F P
Regression 3 0.0000001 0.0000001 0.0000000 5.5130 0.005295
Wt% 1 0.0000000 0.0000000 0.0000000 0.0002 0.0988197
Load (N) 1 0.0000001 0.0000001 0.0000001 14.5651 0.000886
Speed (rpm) 1 0.0000000 0.0000000 0.0000000 1.9736 0.0173428
Error 23 0.0000001 0.0000001 0.0000000

Table 4. Response Table for Means.

Level Wt% Load (N) Speed (rpm)
1 89.54 102.19 99.22
2 88.04 84.97 82.59
3 87.79 78.20 83.56
Delta 1.75 24.00 16.63
Rank 3 1 2

3.4. Response table for signal to noise ratios

Table 4 shows the wear rate response table of means for smaller is better. It indicates that
load (ranked −1) is highest influence on wear rate followed by speed (ranked-2) and wt%
(ranked −3) of ceramic particles. In dry sliding wear test of hybrid composites, occur­
rence of a hard layer on the wear surface supports wear resistance of the composite,
simultaneously, increasing the temperature at the wear surface due to increases in load
and sliding speed. It is observed that boron particles may be entrenched into the soft
aluminium composite resulting in formation of a film that may get crushed under the
applied load at the wear surface. This thin film wears out from time to time and forms
wear debris on the disc. Therefore the effect of temperature varies the surface hardness
and performance of the mono and hybrid composites resulting in early failure of the
component. However, the presence of graphite particles reduces the friction and thereby
the temperature between the pin and disc reduces resulting in prevention of formation of
re-crystallisation in the worn surface. Therefore in hybrid composites, load and sliding
speeds are most significant followed by Wt% of boron and graphite.

3.5. Scanning electron microscopy

The worn surface on the specimen is seen using Scanning Electron Microscopy in Al6061
composites with 2% graphite and 2% Boron against a steel disc at 800 RPM, load 40 N. The
morphology of the worn surface of a composite shown in Figure 12. Material loss with wear
is substantial, according to the sample. Because the steel disc particles pierce the pin, wear
on the pin is enhanced. At higher loads, hard boron carbide particles remove more material
from the worn surface. Delamination is the cause of the occurrence. Extra material is
removed from the pin at high temperatures due to material softening [18]. At higher
temperatures, delamination wear is more evident.
From Figure 12A a non uniform wear comprising of furrows, small scale cuttings and
scratch marks, shaped by the fortifying materials have been seen in composite specimens after
wear. This demonstrates the wear of the composites has been because of the scraped spot
wear.
 ADVANCES IN MATERIALS AND PROCESSING TECHNOLOGIES 13

Figure 12. (a) Worn out surface micrograph for wear rate of Al6061 with 2% graphite for sliding Speed
800rpm, load 40 N. (b) Worn out surface micrograph for wear rate of Al6061 with 2% graphite and 2%
boron for sliding speed 800rpm, load 40 N.

From the SEM image Figure 12B, it can seen that boron particles are dispersed in the
matrix and this are fractured. This is further confirmed by wear study carried out by
B. Manjunatha, et al. [19]. More grooves were observed, indicating a change from normal
wear to severe wear, resulting in a high rate of heavy metal loss [20]. The plastic
deformation between the revolving disc and the composite specimen at high load caused
this wear mechanism, resulting in a high wear rate.

4. Conclusions
Based on experimental results, the following conclusions are drawn.

● Metal matrix mono (Al-6061/2% B), (Al-6061/2% Gr) and Hybrid (Al-6061/2% B/
2% Gr) composites can be effectively produced by stir casting technique.
● The Taguchi method employed in this study is an effective tool for modelling the
wear behaviour of composites.
● The hybrid composite showed better wear resistance under the parameters tested
and compared to mono composites.
● Based on results, load and sliding speed were found to have more significant effect
on the sliding wear of the specimens.
● The addition of boron reinforcement in mono composite increases the hardness and
strength. But, adding graphite particles in hybrid composites leads to reduction in
defects level and improvement in wear resistance and also results in improved
lubrication of the wear surface.
● Scanning electron microscopic study of the worn out surfaces of the composites
showed developed wear tracks based on which wear mechanism could be studied
besides dispersion in the Al 6061 matrix and fracture of these particles. This
suggested that the wear mechanism is strongly dictated by the presence of B4C
particles in the matrix.
14 N. D ET AL.

Acknowledgments
The authors wish to appreciate Visvesvaraya Technological University, Belagavi and Sai Vidya
Institute of Technology for their support.

Disclosure statement
No potential conflict of interest was reported by the author(s).

Funding
The authors received no funding for this research.

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