Tribological Behavior of AA7050-ZrSiO4 Composites Synthesized by Stir Casting Technique

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Abstract

This research made an attempt to synthesize aluminum metal matrix composites through stir casting technique. The matrix material chosen in this study was AA7050 and the reinforcement material was ZrSiO4. The composites AA7050, AA7050-10%ZrSiO4, and AA7050-15%ZrSiO4 were used. The wear behavior of the aluminum matrix composites was investigated by using pin-on-disc tribometer. The advanced material has substantial development in tribological behavior when the reinforcement percentage is increased. From the experimental results, it was confirmed that sliding distance of 1200 m, applied load of 3 N and sliding speed of 2 m/s result in minimum wear loss and coefficient of friction, while adding 10%ZrSiO4 to the AA7050.

Abstract

This research made an attempt to synthesize aluminum metal matrix composites through stir casting technique. The matrix material chosen in this study was AA7050 and the reinforcement material was ZrSiO4. The composites AA7050, AA7050-10%ZrSiO4, and AA7050-15%ZrSiO4 were used. The wear behavior of the aluminum matrix composites was investigated by using pin-on-disc tribometer. The advanced material has substantial development in tribological behavior when the reinforcement percentage is increased. From the experimental results, it was confirmed that sliding distance of 1200 m, applied load of 3 N and sliding speed of 2 m/s result in minimum wear loss and coefficient of friction, while adding 10%ZrSiO4 to the AA7050.

1 Introduction

Aluminum matrix composites with enhanced properties are most desirable in the field of aerospace and automotive field [1]. Nowadays, due to various advances in the field of engineering and its applications, metal matrix composites possess several advantages. When we compare particulate reinforced MMCs with fiber strengthened MMCs, the particulate reinforced MMCs cost much lesser. Zircon strengthened composites retain better confrontation to abrasion; these are also thermal resistant and free from chemical occurrences [2]. MMCs proved that it has greater tribological and mechanical properties in various engineering applications [3]. Due to its high strength, high stiffness and wear resistance, aluminum based composites have been accredited as superior material in all the engineering fields [4]. The aluminum alloy based composites are especially being used as automobile components manufacturing such as piston, connecting rod, microwave filters, vibrator component, contactors, impellers and space structures because of its extended properties [5]. Stir casting technique is one of the promising techniques to manufacture MMCs in large quantities. Owing to its easiness and litheness, it has been fascinated. Complicated components with proper distribution of particulates in the matrix material can be fabricated by stir casting method [6, 7, 8, 9].

In this study, aluminum metal matrix composites have been fabricated through the stir casting technique and the tribological behavior has been investigated.

2 Experimental Details

2.1 Materials

The aluminum alloy AA7050 was used as a matrix material, its chemical composition and properties are presented in Table 1 and Table 2. ZrSiO4 was used as a reinforcement material and its properties are presented in Table 3.

Table 1

Chemical composition of AA7050

AA7050SiFeCuMnMgCrZnTiPbSrZrAl
Weight (%)0.0610.1391.6290.1052.5430.2185.2430.0840.0220.0020.003Bal

Table 2

Mechanical properties of AA7050

PropertiesAA7075
Density2.83 g/cc
Ultimate tensile strength524 Mpa
Melting point629°C

Table 3

Mechanical properties of ZrSiO4

PropertiesZrSiO4
Density3.9 g/cm3
Ultimate tensile strength290 Mpa
Melting point2550°C

2.2 Preparation of composites

The composites were prepared through liquid metallurgy method. Initially, the matrix material AA7050 was melted in a crucible furnace. The temperature maintained in the furnace was 800°C for a time period of 4 hours. Before pouring the ZrSiO4 into the melt, it was preheated at a temperature of 150°C. Finally, the essential amount of ZrSiO4 was mixed with AA7050 to make a cast. At that time, the stirring speed was maintained at 300–500 rpm [10]. The temperature maintained was 750° C and stirring was done for a time period of 10 min.

Figure 1
Figure 1

Experimental setup of stir casting

Citation: Mechanics and Mechanical Engineering 23, 1; 10.2478/mme-2019-0026

2.3 Wear behavior

The wear behavior of the different composites was investigated by using a pin-on-disc tribometer. The experiments were conducted under dry conditions at different loads and speeds to investigate the wear behavior such as friction loss and co-efficient of friction for different composites.

Figure 2
Figure 2

Load versus wear loss

Citation: Mechanics and Mechanical Engineering 23, 1; 10.2478/mme-2019-0026

Figure 3
Figure 3

Load versus COF

Citation: Mechanics and Mechanical Engineering 23, 1; 10.2478/mme-2019-0026

3 Results and Discussions

The wear loss and coefficient of friction behaviors of AA7050, AA7050-10%ZrSiO4, and AA7050-15%ZrSiO4 were investigated by using pin-on-disc apparatus. The experiments were done at different loads of 3 N, 6 N, 9 N, 12 N and 15 N, different sliding distances of 1200 m, 1700 m, 2200 m, 2700 m and 3200 m, and different sliding speeds of 0.4 m/s, 0.8 m/s, 1.2 m/s, 1.6 m/s and 2.0 m/s.

The experimental results showed that when the applied load was increased, the wear loss also increased. The results of wear loss and coefficient of friction against load and sliding speed are listed in Table 4 and Table 5. The least wear loss of 0.0154 gm and least coefficient of friction of 0.165 μ were achieved for AA7050-10%ZrSiO4 composite, while applying a load of 3 N. From the graphs, it was clear that at high sliding speed, wear loss and coefficient frictions were minimum. At a sliding speed of 2 m/s, the least wear loss achieved was 0.0159 g and least coefficient friction was 0.161, identified for the composite AA7050-10%ZrSiO4.

Figure 4
Figure 4

Sliding speed versus wear loss

Citation: Mechanics and Mechanical Engineering 23, 1; 10.2478/mme-2019-0026

Figure 5
Figure 5

Sliding speed versus COF

Citation: Mechanics and Mechanical Engineering 23, 1; 10.2478/mme-2019-0026

Table 4

Wear loss (gm) and coeflcient of friction (μ) for applied load (N)

Applied Load (N)AA7050AA7050-10%ZrSiO4AA7050-15%ZrSiO4

Wear Loss (gm)Coefficient of Friction to (μ)Wear Loss (gm)Coefficient of Friction to (μ)Wear Loss (gm)Coefficient of Friction to (μ)
30.01750.1850.01540.1650.01610.168
60.01820.1940.01620.1690.01730.176
90.01900.2030.01700.1750.01820.182
120.01990.2130.01840.1850.01950.188
150.02070.2190.01910.1930.02080.197

Table 5

Wear loss (gm) and coeflcient of friction (μ) for sliding speed (m/s)

Sliding speed (m/s)AA7050AA7050-10%ZrSiO4AA7050-15%ZrSiO4

Wear Loss (gm)Coefficient of Friction to (μ)Wear Loss (gm)Coefficient of Friction to (μ)Wear Loss (gm)Coefficient of Friction to (μ)
0.40.01860.1960.01880.1850.01920.197
0.80.01780.1880.01820.1790.01850.191
1.20.01700.1770.01760.1750.01800.186
1.60.01690.1700.01690.1670.01740.181
2.00.01650.1640.01590.1610.01700.175

4 Conclusions

  1. The aluminum metal matrix composites with different reinforcement weight percentage were successfully fabricated through stir casting technique.
  2. The wear properties such as wear loss and friction coefficient were influenced by 10%ZrSiO4.
  3. The least wear loss and coefficient friction was detected for the composite AA7050-10%ZrSiO4 with an applied load of 3 N.
  4. The least wear loss and coefficient friction was attained for the composite AA7050-10%ZrSiO4 at a sliding speed of 2 m/s.

References

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    Shanmughasundaram P.: Effect of temperature load and sliding velocity on the wear behavior of AA7075-SiC composites Mechanics and Mechanical Engineering 21 85–93 2017.

  • [2]

    Satish Kumar Thandalam Subramanian Ramanathan Shalini Sundarrajan: Synthesis microstructural and mechanical properties of ex situ zircon particles (ZrSiO4) reinforced Metal Matrix Composites (MMCs): a review Journal of Materials Research Technology 4 333–347 2015.

    • Crossref
    • Export Citation
  • [3]

    Karamis M. B. Alper Cerit A. Burhan Selcuk Fehmi Nair: The effects of different ceramics size and volume fraction on wear behavior of Al matrix composites (for automobile cam material) Wear 289 73–81 2012.

    • Crossref
    • Export Citation
  • [4]

    Veeresh Kumar G. B. Rao C. S. P. Selvaraj N. Bhagyashekar M. S.: Studies on Al6061-SiC and Al7075-Al2O3 Metal Matrix Composites Journal of Minerals & Materials Characterization & Engineering 9 43–55 2010.

    • Crossref
    • Export Citation
  • [5]

    Ramesh C. S. Anwar Khan A. R. Ravikumar N. Savanprabhu P.: Prediction of wear coefficient of Al6061-TiO2 Composites Wear 259 602–608 2005.

    • Crossref
    • Export Citation
  • [6]

    Balasivanandha Prabu S. Karunamoorthy L. Kathiresan S. Mohan B.: Influence of stirring speed and stirring time on distribution of particles in cast metal matrix composite Journal of Materials Processing Technology 171 268–273 2006.

    • Crossref
    • Export Citation
  • [7]

    Hashim J. Looney L. Hashmi M. S. J.: Metal matrix composites: production by the stir casting method Journal of Materials Processing Technology 92 1–7 1997.

  • [8]

    Hashim J. Looney L. Hashmi M. S. J.: Particle distribution in cast metal matrix composites Part 1 Journal of Materials Processing Technology 123 251–257 2002.

    • Crossref
    • Export Citation
  • [9]

    Ourdjini A. Chew K. C. Khoo B. T.: Settling of silicon carbide particles in cast metal matrix composite Journal of Materials Processing Technology 116 72–76 2001.

    • Crossref
    • Export Citation
  • [10]

    Ravichandran M. Dineshkumar S.: Synthesis of Al-TiO2 composites through liquid powder metallurgy route SSRG International Journal of Mechanical Engineering 1 12–17 2014.

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  • [1]

    Shanmughasundaram P.: Effect of temperature load and sliding velocity on the wear behavior of AA7075-SiC composites Mechanics and Mechanical Engineering 21 85–93 2017.

  • [2]

    Satish Kumar Thandalam Subramanian Ramanathan Shalini Sundarrajan: Synthesis microstructural and mechanical properties of ex situ zircon particles (ZrSiO4) reinforced Metal Matrix Composites (MMCs): a review Journal of Materials Research Technology 4 333–347 2015.

    • Crossref
    • Export Citation
  • [3]

    Karamis M. B. Alper Cerit A. Burhan Selcuk Fehmi Nair: The effects of different ceramics size and volume fraction on wear behavior of Al matrix composites (for automobile cam material) Wear 289 73–81 2012.

    • Crossref
    • Export Citation
  • [4]

    Veeresh Kumar G. B. Rao C. S. P. Selvaraj N. Bhagyashekar M. S.: Studies on Al6061-SiC and Al7075-Al2O3 Metal Matrix Composites Journal of Minerals & Materials Characterization & Engineering 9 43–55 2010.

    • Crossref
    • Export Citation
  • [5]

    Ramesh C. S. Anwar Khan A. R. Ravikumar N. Savanprabhu P.: Prediction of wear coefficient of Al6061-TiO2 Composites Wear 259 602–608 2005.

    • Crossref
    • Export Citation
  • [6]

    Balasivanandha Prabu S. Karunamoorthy L. Kathiresan S. Mohan B.: Influence of stirring speed and stirring time on distribution of particles in cast metal matrix composite Journal of Materials Processing Technology 171 268–273 2006.

    • Crossref
    • Export Citation
  • [7]

    Hashim J. Looney L. Hashmi M. S. J.: Metal matrix composites: production by the stir casting method Journal of Materials Processing Technology 92 1–7 1997.

  • [8]

    Hashim J. Looney L. Hashmi M. S. J.: Particle distribution in cast metal matrix composites Part 1 Journal of Materials Processing Technology 123 251–257 2002.

    • Crossref
    • Export Citation
  • [9]

    Ourdjini A. Chew K. C. Khoo B. T.: Settling of silicon carbide particles in cast metal matrix composite Journal of Materials Processing Technology 116 72–76 2001.

    • Crossref
    • Export Citation
  • [10]

    Ravichandran M. Dineshkumar S.: Synthesis of Al-TiO2 composites through liquid powder metallurgy route SSRG International Journal of Mechanical Engineering 1 12–17 2014.

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