Optimizing the Dry Sliding Wear Behavior of Stir-Casted Al6061/Nano-Al<sub>2</sub>O<sub>3</sub>/Quartz Hybrid Metal Matrix Composite Using Taguchi Method

Tirfe, Dagim; Debebe Woldeyohannes, Abraham; Regassa Hunde, Bonsa; Batu, Temesgen; Geleta, Eaba

doi:https://doi.org/10.1155/2024/3589701

Advances in Tribology

On this page

Abstract Introduction Materials and Methods Discussion Conclusion Data Availability Conflicts of Interest References Copyright Related Articles

Research Article | Open Access

Volume 2024 | Article ID 3589701 | https://doi.org/10.1155/2024/3589701

Optimizing the Dry Sliding Wear Behavior of Stir-Casted Al6061/Nano-Al₂O₃/Quartz Hybrid Metal Matrix Composite Using Taguchi Method

Dagim Tirfe,^1,2Abraham Debebe Woldeyohannes,¹Bonsa Regassa Hunde,¹Temesgen Batu,²and Eaba Geleta²

Academic Editor: Mohammad Farooq Wani

Received16 Oct 2023

Revised25 Jan 2024

Accepted14 Feb 2024

Published29 Feb 2024

Abstract

The increased demand for wear-resistant and low-weight components in the automobile industry has led to the utilization of aluminum metal matrix composite parts due to their improved performance. The current work focused on optimizing the tribological factors such as applied load, rotational speed, and percentage weight fraction of the reinforcing particles for minimum dry sliding wear rate of Al6061/nano-Al₂O₃/quartz hybrid composite fabricated by stir casting. The optimization is performed by using the Taguchi L₂₇ orthogonal array experimental plan, and the result is analyzed by the help of analysis of variance (ANOVA). The result of the optimization reveals that the optimum levels of factors for the minimum wear rate are 10 N, 200 rpm, and 12.5%. Furthermore, the ANOVA result depicts that the applied load has the highest impact (87.83%) on the wear rate, followed by rotational speed (10.06%) and percentage weight fraction of the reinforcement (1.60%). The developed linear regression model reveals that the applied load and the rotational speed have a positive relation with the sliding wear rate. However, the percentage weight fraction of the reinforcement has a negative relation. The confirmation test proves that the predicted value of wear rate using the regression equation at optimum levels has a closer agreement with the experimental result having a 6.934% error. Furthermore, the physical property test reveals that the rise in the weight percentage of quartz particles results in a corresponding increase in the percentage porosity of the hybrid composite.

1. Introduction

A composite material is described as a structural material produced synthetically or artificially by fuzing two or more insoluble components with different properties. Compared to any of their basic materials, composite materials have better characteristics [1]. It is one of the most advanced classes of engineering materials in which the reinforcing phase is embedded in the matrix phase. The individual phases retain their properties in the final fabricated structure. The properties of the composite materials depend on the particle size and, consequently, the degree of dispersion of the individual composite particles [2]. The reinforcement material possesses much better properties compared to the matrix material. However, the matrix is used to bind the reinforcements together and conserve the integrity of the combined material, and it creates the primary structure of the composite material [2].

The property requirement of the composite, wettability of the reinforcement in the matrix phase, and thermodynamical compatibility of the reinforcement with the matrix are some of the basic criteria for the selection of reinforcement in a specific metal matrix composite (MMC) [3, 4]. A good balance of strength, toughness, density, and tribological parameters like wear rate and coefficient of friction cannot be achieved by utilizing conventional monolithic materials [5–8].

A MMC is a composite made up of at least two basic components, one of which is a metal. The second component could be another metal, a ceramic, fiber, or an organic material [9]. They function well in applications where a combination of strength, thermal conductivity, damping properties, and a low coefficient of thermal expansion with low density were required [10, 11]. Metallic materials such as Al, Ti, Fe, Cu, and Ni are used as a matrix in MMCs [12], and ceramic materials (Al₂O₃, SiC, BN, SiO₂, B4C, TiB₂, ZrO₂, Quartz, clay, and fly ash) are used as a reinforcing phase [13, 14]. In the case of MMC, the reinforcing phase can be a single phase or a multiple phase [15–17]. Aluminum and its alloys are by far the most common MMC materials, both in research and development and in industry applications [18]. Composites made of aluminum alloys belong to the category of lightweight, high-performance engineered materials that can offer a variety of benefits when used as a structural material [19–21].

Composition, relative wettability, and distribution of the reinforcing ceramic particles in the matrix phase and production cost are some of the important factors that are considered while selecting specific manufacturing techniques to develop aluminum metal matrix composite (AMMC) [22]. Particulate-reinforced AMMCs can be successfully fabricated by both liquid phase (stir casting, infiltration process, squeeze casting) and solid phase (powder metallurgy, friction stir process, spark plasma) fabrication routes [23–27]. Even if these two fabrication methods produce an AMMC, to get a sound product with a minimum amount of defects, the appropriate selection of the following processing parameters was very crucial: selection of appropriate manufacturing technique, appropriate selection of processing parameters (type, percentage content and particle size of the reinforcement, melting temperature, sintering temperature and time, press pressure, stirring speed, stirring time), and appropriate selection of secondary manufacturing process such as machining and joining [28–30].

In terms of fabrication cost and process simplicity, stir casting has an advantage over other fabrication methods of AMMCs [28, 31]. Even if this method has some drawbacks, it can be reduced by using several techniques such as the double stir casting method [32], adding wetting enhancing elements such as magnesium, applying secondary operations such as forging, extrusion, and heat treatment process [33], and selecting optimum processing parameters. Preheating of the reinforcing particle and the metallic mold at the appropriate level of temperature is the other method of reducing oxidation and enhancing the microstructural integrity of the composite [34]. Some related published articles on the areas of optimization of the sliding wear rate of aluminum matrix composites, including their optimization technique and optimized parameters for the minimum sliding wear rate, are reviewed in Table 1.

In different manufacturing industries such as aerospace, automotive, marine, defense, and electronics, the demand for AMMC is rapidly increased due to its improved mechanical properties [47–49]. In the automotive industry, AMMCs are highly utilized to manufacture different parts of lightweight cars, such as braking system components, engine components, automotive body components, transmission system components, and structural parts [50–52]. Lightweight, improved wear resistance, improved thermal properties, and low cost of aluminum matrix composite for automotive components are the primary reasons for its widespread use in comparison to other materials [6, 53]. The most promising use for AMMC in the near future is the replacement of traditional automotive materials like steel and cast iron in brake systems and unsprung weight components like car engines [47, 51].

In general, the objective of the present paper is to fabricate a new class of hybrid AMMC and to optimize the dry sliding wear behavior of Al6061/nano-Al₂O₃/quartz hybrid composites using the Taguchi technique. The paper addresses the development of a new hybrid MMCs using the stir casting technique and a practical experiment of dry sliding wear test on a pin-on-disc wear testing machine in order to assess the performance of the developed composite. Furthermore, this research studied the effect of naturally occurring micro quartz particles in combination with nano-Al₂O₃ and other tribological parameters on the dry sliding wear rate of the hybrid composite, which had not been studied before. Finally, the optimization is performed by using the Taguchi technique, and the result is analyzed by the help of analysis of variance (ANOVA), and the optimization is validated by performing a confirmation test at the optimum level of the factors, and the confirmation test report is presented in the conclusion part.

2. Materials and Methods

2.1. Materials

Due to the presence of a high amount of Si and Mg elements in Al6061, as shown in Table 2, it has a better wear resistance property compared to other types of aluminum alloys [55], and it is used as a matrix material in this study. The modern automotive industries have developed different lightweight automotive components such as brake and clutch discs from Al6061 [56, 57]. In addition, Al₂O₃ is the first corrosion-resistant due to the presence of an oxide layer and the second wear-resistive ceramic material next to silicon carbide [58, 59]. In addition to Al₂O₃, microquartz particles were used as the second reinforcing ceramic particles to form a hybrid composite. As it is stated in different articles, quartz is the second toughest material, and as a result, it has better wear resistance properties [60–65]. About 50 nm and 45 μm particle sizes of Al₂O₃ and quartz were used for the development of the composite. The mixture design of the matrix and reinforcement during the preparation of the composite are depicted in Table 3.

2.2. Methods

2.2.1. Preparation of the Composite Samples

The hybrid composite was developed using the stir casting technique of manufacturing. The four-blade mixer was created using a stainless-steel bar that is chrome-plated and operated by a Nama 21 stepper motor. The speed and duration of the stirring were regulated by an Arduino Mega microcontroller with the help of Mach 3 CNC Controller software. The composition of the developed hybrid composite is depicted in Table 2.

Figure 1 shows the fabrication sequence of the developed hybrid aluminum matrix composite. Initially, the nano Al₂O₃ particles were heated beforehand and then fuzed at a temperature of 500°C. These particles were then introduced into the liquid metal at a consistent rate of 5% for each casting. Following this, the mixture of aluminum and aluminum oxide was supplemented with quartz powder, which had a particle size of 45 μm, at a continuous rate of 3%, 6%, and 9% based on the weight of the Al alloy matrix. The mixture of liquid aluminum alloy and reinforcements was constantly mixed for a duration of 5 min at a speed of 400 revolutions per minute using a specifically designed mixer to evenly disperse the reinforcements throughout the alloy. Afterward, the liquid metal is swiftly poured into three metallic permanent molds having 110 mm in height and 10 mm in diameter, resulting in a highly efficient process with a large output. Once the solidification process is complete, the mold is secured with splints, and the specimen is removed. The process was carried out three additional times in the same manner in order to achieve varying levels of reinforcement. Finally, the cast samples were machined into a standard specimen using a lath machine as per ASTM G99, which has a height of 12 mm and a diameter of 6 mm.

2.2.2. Design of Experiment for Testing

(1) Physical Property Test. The physical property test is performed in order to determine the porosity level of the developed composite by determining the density. Both theoretical and experimental densities were conducted on the developed three composite samples shown in Table 3 to examine how the densities of the produced composites are affected by the different weight fractions of nano-Al₂O₃ and quartz particles. The theoretical density of the composites was calculated using the rule of mixture, while the experimental density was measured by weighing the test sample with a digital weighing balance and then dividing the weight by the volume of the respective test sample. The composites’ porosity percentage was measured by comparing their experimental and theoretical densities using Equation (1).where ƍT is the theoretical density (in g/cm³) and ƍEx is the experimental density (in g/cm³).

(2) Dry Sliding Wear Test. A major step involved in the DOE process is the determination of the combination of factors and levels, which will give the desired information about the total experimental run to be performed [66]. The DOE, under Taguchi’s technique, is proposed for designing the experiments for the sliding wear test in order to reduce the total experimental time by performing a minimum number of experiments. The flow of the optimization technique for the current study is shown in Figure 2. Taguchi used orthogonal arrays to design the experiments for the combination of different number of factors and different number of levels.

A well-balanced design with a minimum number of experiments is provided by an orthogonal array for a particular combination. Dry sliding wear test will be performed with three parameters: applied load, rotational speed, and wt.% fraction of the reinforcement by varying them for three levels, which is shown in Table 4.

The aim of the experimental plan is to find the important factors and the combination of factors influencing the wear process to obtain the minimum sliding wear rate and coefficient of friction. The experiments were developed based on an orthogonal array, with the aim of relating the influence of applied load, rotational speed, and percentage weight fraction of the reinforcement.

L₂₇ orthogonal array, as shown in Table 5, is selected for the current experimentation due to the fact that L₂₇ allows factor interaction in addition to the main effect, and it increases the accuracy of the analysis compared to L₉ as it only tells the main effect. The tribological responses for the current investigation are sliding wear rate and coefficient of friction. The intention is to minimize the dry sliding wear rate signal-to-noise (S/N) ratio value calculated by considering the condition of the “smaller is the better” approach using Equation (2).

where y₁, y_2……y_n are the response of sliding wear, and n is the number of observations.

In order to determine the sliding wear rate of the fabricated hybrid composite based on Equation (3), the mass losses after pin-on-disc wear testing of the composite were performed by using a high-precision analytical balance with a readability of 0.1 mg, which is produced by WANT Balance Instrument Co., Ltd. Furthermore, a contact pressure of 0.4 Mpa and a disc with a contact diameter of 74 mm having 56 HRC were used during the experiment.where W_r is the dry sliding wear rate of the hybrid composite (mm³/m), Δm is the change in mass of the composite specimen after the test (kg), ƍ is the density of the developed hybrid composite (kg/mm³), and L is the sliding distance at which the wear test is performed (mm).

3. Result and Discussion

The experimental results of the physical test, including density and porosity, were presented in this section. Furthermore, the results of the tribological test were analyzed with ANOVA, which is used to investigate the influence of the considered wear parameters, namely, applied load, sliding speed, and sliding distance that significantly affect the performance measures. By performing ANOVA, it can be decided which independent factor dominates over the other and the percentage contribution of that particular independent variable.

3.1. Physical Properties

The physical characteristics of the developed hybrid MMC samples were analyzed and displayed in Figure 3. The decline in the theoretical density of samples S₁–S₃, as shown in Figure 3(a), can be attributed to the decrease in the weight percentage of Al6061 and the increase in the weight percentage of quartz particles, which is in line with the result of Vijayakumar et al.’s [67] study. Quartz particles have a lower density compared to Al6061 and Al₂O₃, which explains the gradual reduction in sample density. The result of the experimental density shown in Figure 3(b), depicts that as the weight percentage of the reinforcing particles increases, the density of the composite decreases as a result of porosity, which is proved by Figure 3(c), the highest amount of percentage porosity was observed in sample S3, which was 3.6% due to the increment of air bubbles in the contact surface area between the matrix alloy and the reinforcement particulates. However, the obtained porosity levels were within the accepted limit since it was below 4% [67, 68].

(a)

(b)

(c)

3.2. Dry Sliding Wear Behavior of the Hybrid Composite

The current study investigates the dry wear rate and coefficient of friction of Al6061/nano-Al₂O₃/quartz hybrid MMC under different tribological factors and levels. The tribological parameter’s that are varied during the experimental investigation are the applied load (10, 20, and 30 N), rotational speed (200, 300, and 400 rpm), and percentage weight fraction of the reinforcement particles in the composite (6.5%, 9.5%, and 12.5%) keeping the other parameters’ constant. The results of the dry sliding wear rate test conducted as per the L₂₇ orthogonal array experimental plan are depicted in Table 6 with their corresponding S/N ratio of each test.

3.3. S/N Ratio of Each Spacemen

The S/N ratio of each test sample is obtained to study the impact of each tribological parameter, such as applied load, rotational speed, and percentage weight fraction of the reinforcement on the dry sliding wear rate of Al6061/nano Al₂O₃/quartz hybrid composite. In order to obtain the minimum wear rate, a “smaller-the-better “scenario is utilized for the study. The difference between the two extremes of each factor is ranked by the delta value, which is depicted in Table 7. The delta rank of the S/N ratio value shows that the applied load has the highest impact on the sliding wear rate of the hybrid composite, followed by the rotational speed and percentage weight fraction of the reinforcing particles. The results of the main effect plots for the S/N ratio and means shown in Figure 4 reveal that the optimum levels of the factors for minimum wear rate are 10 N, 200 rpm, and 12.5% for applied load, rotational speed, and percentage weight fraction, respectively. The result of the study is supported by Prasad et al. [69], stating that the addition of 5 wt.% nano-Al₂O₃ improves the wear resistance of the matrix by 55%, and the improvement is achieved due to the uniform distribution of the Al₂O₃ particles throughout the base aluminum matrix alloy. Furthermore, Ogunrinola et al. [62] reported that the addition of 9% quartz particles in LM25 aluminum alloy improves the wear resistance of the alloy by 132.2% due to the fact that the ceramic particles form a hard phase in the matrix.

(a)

(b)

3.4. ANOVA for Wear Rate

In order to identify the percentage contribution of each tribological factor on the sliding wear rate, the ANOVA for the test is performed with the help of Minitab 14 statistical analysis software, and this analysis is performed at a level of 5% significance that is up to a confidence level of 95%. As observed in Table 7, the ANOVA table depicts that the applied load has an extremely higher impact, with a percentage contribution of 87.83% compared to the other factors. The rotational speed is the second influencing factor with a percentage contribution of 10.06%, followed by the weight percentage of the reinforcing particles having a 1.60% contribution on the sliding wear rate Al6061/nano-Al₂O₃/quartz hybrid composite. The percentage contribution of each factor was depicted in the last column of the ANOVA table. As it is reported by Kumar et al. [70], whenever the P value in the ANOVA table is below 0.5, it indicates that the specific factor has the highest effect on the response. As shown in Table 7, since the P value of the applied load and rotational speed is much lower than 0.5, they will have a higher effect on the sliding wear rate compared to that of the weight fraction of the reinforcement, which has a P value higher than 0.5. As observed from the wear test as well as the main effect plot, it was noticed that the amount of wear increased as the applied load increased for all combinations of materials (S₁, S₂, and S₃). This was because the rough surfaces pushed harder into the softer surfaces (sample pins) as the load increased. Furthermore, at elevated loads, the smoother areas on the surface may experience plastic deformation and breakage, causing the transfer of material between the surfaces in contact due to the rise in temperature. Consequently, this leads to an increase in wear loss. The work of Pattanaik et al. [71] supports the current result of the investigation.

3.5. Multiple Linear Regression Model

The mathematical relationships between factors and the response (sliding wear rate) were developed through multiple regression models with the help of the Minitab 14 software. This regression model, which is shown in Equation (4), is a linear equation that gives the relation between the independent variables, such as the applied load, rotational speed, and weight percentage of the reinforcing particles, with the dependent variable sliding wear rate. As it is observed from the regression equation, the coefficients of the applied load and rotational speed are positive, indicating that these two factors have a positive relationship with the wear rate. However, the weight percentage of the reinforcing particles has a negative coefficient, which implies that this factor has an inverse relation with the wear rate. This is due to the fact that both Al₂O₃ and quartz are a type of ceramics known for their exceptional hardness and ability to bear heavy loads [40, 72, 73]. When these solid particles are incorporated into the soft aluminum matrix, they function as an additional phase and hinder the ability to shape the material [72, 74, 75]. As a consequence, the hybrid composites exhibit noticeable enhancements in resistance to wear.

3.6. Confirmation Test

The final step in any optimization problem is confirming the quality characteristics of the response by implementing the optimum levels of each process or design parameters or factors. This prediction of the optimum response is determined by the help of the developed linear regression model. Therefore, the optimum level of the sliding wear rate is obtained by substituting the optimum levels of each factor in the linear regression Equation (4). The predicted optimum wear rate with its optimum levels is depicted in Table 8.

In order to confirm the predicted value of sliding wear rate, which is calculated by substituting the optimum levels in the regression model, a confirmation pin-on-disc wear test is performed once again at the optimum level of factors, and the result with percentage error is depicted in Table 9.

The result of the confirmation test reveals that the predicted value of the sliding wear rate at the optimum levels of the factors has a closer agreement with the experimental result, having a 6.934% error. As it is reported by Samal et al. [2], Rao and Ponugoti [8], J. Singh et al. 2014 [76], Baskaran et al. [77], and Uraraga et al. [78], a percentage of error of less than 8% between the predicted and experimental results indicates that the developed design of the experiment was successful in determining the response (wear rate) from the regression model.

4. Conclusion

The dry sliding wear tests were conducted by using a pin-on-disc wear testing machine on the stir-cast Al6061/nano-Al₂O₃/quartz hybrid MMCs containing a fixed 3.5 wt.% of nano-Al₂O₃ and a varying (3, 6, and 9) weight percentage of microquartz particles using a Taguchi L₂₇ orthogonal array design. The following conclusions are drawn from this experimental study.(i)Al6061/nano-Al₂O₃/quartz hybrid MMC was successfully developed by the help of a stir casting technique by varying the weight percentage of the reinforcing particles.(ii)The variation in the applied load, rotational speed, and weight percentage of the reinforcing hard particles are responsible for the change in the wear test results that are observed during the pin-on-disc wear test.(iii)The optimum combination of levels for minimum dry sliding rate as observed from the main effect plot, 10 N applied load, 200 rpm rotational speed, and 12.5% of the reinforcing ceramic particles.(iv)The ANOVA result depicts that the applied load has a maximum effect on the sliding wear rate of the developed hybrid composite, having 87.83% contribution, followed by the rotational speed, having 10.06% contribution.(v)The confirmation test reveals that the predicted value of the sliding wear rate at optimum levels of factors has a closer agreement with the experimental result, having 6.934% error. The result shows that the design of the experiment conducted with the help of the Taguchi technique was successful for determining the dray sliding wear rate from the regression equation.(vi)The physical property of the developed hybrid composite proves that the increase in the percentage weight fraction of the quartz particles increases the porosity level of the hybrid composite.

Data Availability

The data presented in this study are available on request from the corresponding author.

Conflicts of Interest

The authors have no conflicts of interest that affect this work.

References

D. Chandra, N. R. Chauhan, and S. Rajesha, “Hardness and toughness evaluation of developed Al metal matrix composite using stir casting method,” Materials Today: Proceedings, vol. 25, pp. 872–876, 2020.
View at: Publisher Site | Google Scholar
P. Samal, P. R. Vundavilli, A. Meher, and M. M. Mahapatra, “Recent progress in aluminum metal matrix composites: a review on processing, mechanical and wear properties,” Journal of Manufacturing Processes, vol. 59, pp. 131–152, 2020.
View at: Publisher Site | Google Scholar
V. M. Kumar and C. V. Venkatesh, “A comprehensive review on material selection, processing, characterization and applications of aluminum metal matrix composites,” Materials Research Express, vol. 6, no. 7, Article ID 072001, 2019.
View at: Publisher Site | Google Scholar
M. Malaki, A. Fadaei Tehrani, B. Niroumand, and M. Gupta, “Wettability in metal matrix composites,” Metals, vol. 11, no. 7, Article ID 1034, 2021.
View at: Publisher Site | Google Scholar
J. Hashim, L. Looney, and M. S. J. Hashmi, “The enhancement of wettability of SiC particles in cast aluminum matrix composites,” Journal of Materials Processing Technology, vol. 119, no. 1–3, pp. 329–335, 2001.
View at: Publisher Site | Google Scholar
A. M. Razzaq, D. L. A. A. Majid, M. Ishak, and M. B. Uday, “A brief research review for improvement methods the wettability between ceramic reinforcement particulate and aluminum matrix composites,” IOP Conference Series: Materials Science and Engineering, vol. 203, no. 1, Article ID 012002, 2017.
View at: Publisher Site | Google Scholar
P. Chakrapani and T. S. A. Suryakumari, “Mechanical properties of aluminum metal matrix composites—a review,” Materials Today: Proceedings, vol. 45, pp. 5960–5964, 2021.
View at: Publisher Site | Google Scholar
T. B. Rao and G. R. Ponugoti, “Characterization, prediction, and optimization of dry sliding wear behavior of Al6061/WC composites,” Transaction of the Indian Institute of Metals, vol. 74, no. 1, pp. 159–178, 2021.
View at: Publisher Site | Google Scholar
S. P. Singh, K. A. V. Geethan, D. Elilraja, T. Prabhuram, and J. I. Durairaj, “Optimization of dry sliding wear performance of functionally graded Al6061/20% SiC metal matrix composite using Taguchi method,” Materials Today, vol. 22, pp. 2824–2831, 2020.
View at: Publisher Site | Google Scholar
N. K. Chandla, S. Kant, and M. M. Goud, “Mechanical, tribological and microstructural characterization of stir cast Al-6061 metal/matrix composites—a comprehensive review,” Sādhanā, vol. 46, no. 1, pp. 1–38, 2021.
View at: Publisher Site | Google Scholar
P. P. Raj, R. Sridhar, R. Pugazhenthi, G. Anbuchezhiyan, and M. Ganesh, “Investigating the mechanical properties of tungsten carbide metal matrix composites with Al 6061,” Materials Today: Proceedings, vol. 22, pp. 2832–2843, 2023.
View at: Publisher Site | Google Scholar
S. M. George, R. Priya, G. N. S. Vijayakumar, and J. A. Pradeep, “Study on mechanical characteristics of the nano-TiC reinforced Al6061 metal matrix composites,” Materials Today: Proceedings, vol. 62, pp. 2224–2229, 2022.
View at: Publisher Site | Google Scholar
P. V. Reddy, G. S. Kumar, D. M. Krishnudu, and H. R. Rao, “Mechanical and wear performances of aluminum-based metal matrix composites: a review,” Journal of Bio- and Tribo-Corrosion, vol. 6, no. 3, Article ID 83, 2020.
View at: Publisher Site | Google Scholar
K. S. K. Reddy, B. C. Lekha, K. U. Sakshi, M. S. Chouhan, R. Karthikeyan, and S. Aparna, “Effect of different reinforcements on aluminum composite properties—a review,” Materials Today: Proceedings, vol. 62, pp. 3963–3967, 2022.
View at: Publisher Site | Google Scholar
R. Viswanathan, K. G. Saravanan, J. Balaji, R. Prabu, and K. Balasubramani, “Optimization of wear and friction parameters in aluminum7075 hybrid composite,” Materials Today: Proceedings, vol. 47, pp. 4449–4453, 2021.
View at: Publisher Site | Google Scholar
E. B. Moustafa, W. S. Abushanab, A. Melaibari, O. Yakovtseva, and A. O. J. J. Mosleh, “The effectiveness of incorporating hybrid reinforcement nanoparticles in the enhancement of the tribological behavior of aluminum metal matrix composites,” Journal of Materials, vol. 73, no. 12, pp. 4338–4348, 2021.
View at: Publisher Site | Google Scholar
A. Saravanakumar, R. Jeyakumar, S. Boovendravarman, P. Arivalagan, and M. S. Pandian, “Study of tribological characteristics of hybrid aluminum matrix composite using design of experiment,” Materials Today: Proceedings, vol. 63, pp. 2218–2224, 2023.
View at: Publisher Site | Google Scholar
A. Kumar, M. Y. Arafat, P. Gupta, D. Kumar, C. M. Hussain, and A. Jamwal, “Microstructural and mechano-tribological behavior of Al reinforced SiC-TiC hybrid metal matrix composite,” Materials Today: Proceedings, vol. 21, pp. 1417–1420, 2020.
View at: Publisher Site | Google Scholar
V. Rana, H. Kumar, and A. Kumar, “Fabrication of hybrid metal matrix composites (HMMCs)—a review of comprehensive research studies,” Materials Today: Proceedings, vol. 56, pp. 3102–3107, 2022.
View at: Publisher Site | Google Scholar
A. A. Luo, A. K. Sachdev, and D. Apelian, “Alloy development and process innovations for light metals casting,” Journal of Materials Processing Technology, vol. 306, Article ID 117606, 2022.
View at: Publisher Site | Google Scholar
A. Sankhla and K. M. Patel, “Metal matrix composites fabricated by stir casting process—a review,” Advances in Materials and Processing Technology, vol. 8, no. 2, pp. 1270–1291, 2022.
View at: Publisher Site | Google Scholar
P. K. Krishnan, J. V. Christy, R. Arunachalam et al., “Production of aluminum alloy-based metal matrix composites using scrap aluminum alloy and waste materials: Influence on microstructure and mechanical properties,” Journal of Alloys and Compounds, vol. 784, pp. 1047–1061, 2019.
View at: Publisher Site | Google Scholar
Y. Wang and T. Monetta, “Systematic study of preparation technology, microstructure characteristics and mechanical behaviors for SiC particle-reinforced metal matrix composites,” Journal of Materials Research and Technology, vol. 25, pp. 7470–7497, 2023.
View at: Publisher Site | Google Scholar
S. Ranjan and P. K. Jha, “Investigation on the thermodynamic stability of phases evolved in Al-based hybrid metal matrix composite fabricated using in-situ stir casting route,” Journal of Manufacturing Process, vol. 95, pp. 14–26, 2023.
View at: Publisher Site | Google Scholar
A. Bhowmik, D. Dey, and A. Biswas, “Tribological behavior of aluminum–titanium diboride (Al7075-TiB2) metal matrix composites prepared by stir casting process,” Materials Today: Proceedings, vol. 26, pp. 2000–2004, 2020.
View at: Publisher Site | Google Scholar
J. J. M. Hillary, R. Ramamoorthi, and S. J. S. Chelladurai, “Dry sliding wear behavior of Al6061-5% SiC—TiB₂ hybrid metal matrix composites synthesized by stir casting process,” Materials Research Express, vol. 7, no. 12, Article ID 126519, 2020.
View at: Publisher Site | Google Scholar
S. Bahl, “Fiber reinforced metal matrix composites—a review,” Materials Today: Proceedings, vol. 39, pp. 317–323, 2021.
View at: Publisher Site | Google Scholar
P. Morampudi, V. S. N. Venkata Ramana, C. Prasad, K. SriramVikas, and Rahul, “Physical, mechanical and corrosion properties of Al6061/ZrB2 metal matrix nano composites via powder metallurgy process,” Materials Today: Proceedings, vol. 59, pp. 1708–1713, 2022.
View at: Publisher Site | Google Scholar
A. A. Emiru, D. K. Sinha, A. Kumar, and A. Yadav, “Fabrication and characterization of hybrid aluminum (Al6061) metal matrix composite reinforced with SiC, B4C and MoS₂ via stir casting,” International Journal of Metalcasting, vol. 17, no. 2, pp. 801–812, 2023.
View at: Publisher Site | Google Scholar
M. S. Surya, “Effect of SiC weight percentage and sintering duration on microstructural and mechanical behavior of Al6061/SiC composites produced by powder metallurgy technique,” Silicon, vol. 14, no. 6, pp. 2731–2739, 2022.
View at: Publisher Site | Google Scholar
S. Dhanesh, K. S. Kumar, N. K. M. Fayiz, L. Yohannan, and R. Sujith, “Recent developments in hybrid aluminum metal matrix composites: a review,” Materials Today: Proceedings, vol. 45, pp. 1376–1381, 2021.
View at: Publisher Site | Google Scholar
A. Kumar, R. C. Singh, and R. Chaudhary, “Recent progress in production of metal matrix composites by stir casting process: an overview,” Materials Today: Proceedings, vol. 21, pp. 1453–1457, 2020.
View at: Publisher Site | Google Scholar
S. Sivananthan, V. R. Reddy, and C. S. J. Samuel, “Preparation and evaluation of mechanical properties of 6061Al-Al₂O₃ metal matrix composites by stir casting process,” Materials Today: Proceedings, vol. 21, pp. 713–716, 2020.
View at: Publisher Site | Google Scholar
B. C. Kandpal, J. Kumar, and H. Singh, “Fabrication and characterisation of Al2O3/aluminium alloy 6061 composites fabricated by Stir casting,” Materials Today: Proceedings, vol. 4, no. 2, pp. 2783–2792, 2017.
View at: Publisher Site | Google Scholar
S. A. Hasan, M. U. Zaki, and F. Hasan, “Properties & characterization of reinforced aluminum metal matrix composites,” Materials Today: Proceedings, vol. 34, pp. 1132–1144, 2023.
View at: Publisher Site | Google Scholar
S. Arunkumar, R. Ashokkumar, M. S. Sundaram, K. M. SukethKanna, and S. Vigneshwara, “Optimization of wear behavior of Al7075 hybrid metal matrix composites using Taguchi approach,” Materials Today: Proceedings, vol. 33, pp. 570–577, 2020.
View at: Publisher Site | Google Scholar
A. Aabid, M. A. Murtuza, S. A. Khan, and M. Baig, “Optimization of dry sliding wear behavior of aluminum-based hybrid MMC’s using experimental and DOE methods,” Journal of Materials Research and Technology, vol. 16, pp. 743–763, 2022.
View at: Publisher Site | Google Scholar
A. A. Daniel, S. Murugesan, Manojkumar, and S. Sukkasamy, “Dry sliding wear behavior of aluminum 5059/SiC/MoS 2 hybrid metal matrix composites,” Materials Research, vol. 20, no. 6, pp. 1697–1706, 2017.
View at: Publisher Site | Google Scholar
S. Dhanalakshmi, N. Mohanasundararaju, P. Venkatakrishnan, and V. Karthik, “Optimization of friction and wear behavior of Al7075-Al2O3-B4C metal matrix composites using Taguchi method,” IOP Conference Series: Materials Science and Engineering, vol. 314, no. 1, Article ID 012025, 2018.
View at: Publisher Site | Google Scholar
A. D. Sadhana, J. U. Prakash, P. Sivaprakasam, and S. Ananth, “Wear behavior of aluminum matrix composites (LM25/fly ash)—a Taguchi approach,” Materials Today: Proceedings, vol. 33, pp. 3093–3096, 2020.
View at: Publisher Site | Google Scholar
L. Natrayan and M. S. Kumar, “Optimization of wear behavior on AA6061/Al₂O₃/SiC metal matrix composite using squeeze casting technique—statistical analysis,” Materials Today: Proceedings, vol. 27, pp. 306–310, 2020.
View at: Publisher Site | Google Scholar
L. R. Kumar, A. Saravanakumar, V. Bhuvaneswari, G. Gokul, D. D. Kumar, and M. P. J. Karuna, “Optimization of wear behavior for AA2219-MoS2 metal matrix composites in dry and lubricated condition,” Materials Today: Proceedings, vol. 27, pp. 2645–2649, 2020.
View at: Publisher Site | Google Scholar
T. Sathish and S. Karthick, “Wear behavior analysis on aluminum alloy 7050 with reinforced SiC through Taguchi approach,” Journal of Materials Research and Technology, vol. 9, no. 3, pp. 3481–3487, 2020.
View at: Publisher Site | Google Scholar
G. Pitchayyapillai, P. Seenikannan, K. Raja, and K. Chandrasekaran, “Al6061 hybrid metal matrix composite reinforced with alumina and molybdenum disulphide,” Advances in Materials Science and Engineering, vol. 2016, Article ID 6127624, 9 pages, 2016, 2016.
View at: Publisher Site | Google Scholar
P. P. Ikubanni, M. Oki, A. A. Adeleke, and O. O. Agboola, “Optimization of the tribological properties of hybrid reinforced aluminum matrix composites using Taguchi and Grey’s relational analysis,” Scientific African, vol. 12, Article ID e00839, 2021.
View at: Publisher Site | Google Scholar
R. Shanmugavel, T. K. Sundaresan, U. Marimuthu, and P. Manickaraj, “Process optimization and wear behavior of red mud reinforced aluminum composites,” Advances in Tribology, vol. 2016, Article ID 9082593, 7 pages, 2016.
View at: Publisher Site | Google Scholar
M. P. Chakravarthy and D. S. Rao, “Evaluation of mechanical properties of aluminum alloy (AA 6082) reinforced with rice husk ash (RHA) and boron carbide (B4C) hybrid metal matrix composites using stir casting method,” Materials Today: Proceedings, vol. 66, pp. 580–586, 2022.
View at: Publisher Site | Google Scholar
S. T. Mavhungu, E. T. Akinlabi, M. A. Onitiri, and F. M. Varachia, “Aluminum matrix composites for industrial use: advances and trends,” Procedia Manufacturing, vol. 7, pp. 178–182, 2017.
View at: Publisher Site | Google Scholar
V. Srinivasan, S. Kunjiappan, and P. Palanisamy, “A brief review of carbon nanotube reinforced metal matrix composites for aerospace and defense applications,” International Nano Letters, vol. 11, no. 4, pp. 321–345, 2021.
View at: Publisher Site | Google Scholar
V. Chak, H. Chattopadhyay, and T. L. Dora, “A review on fabrication methods, reinforcements and mechanical properties of aluminum matrix composites,” Journal of Manufacturing Processes, vol. 56, pp. 1059–1074, 2020.
View at: Publisher Site | Google Scholar
C. Elanchezhian, B. V. ramanth, G. B. Bhaskar, and M. Vivekanandhan, “An investigation of the mechanical properties of hybrid composites in applications of automotive industry,” Materials Today: Proceedings, vol. 16, pp. 875–882, 2019.
View at: Publisher Site | Google Scholar
P. D. Srivyas and M. S. Charoo, “Application of hybrid aluminum matrix composite in automotive industry,” Materials Today: Proceedings, vol. 18, pp. 3189–3200, 2019.
View at: Publisher Site | Google Scholar
B. S. Babu, P. Prathap, T. Balaji et al., “Studies on mechanical properties of aluminum based hybrid metal matrix composites,” Materials Today: Proceedings, vol. 33, pp. 1144–1148, 2020.
View at: Publisher Site | Google Scholar
A. Srinivasan, R. Prabu, S. Ramesh, and R. Viswanathan, “Investigation and optimization on micro and nano Al₂O₃ reinforced aluminum composites using GRA coupled PCA technique,” Journal of Ceramic Processing Research, vol. 23, no. 6, pp. 783–793, 2022.
View at: Publisher Site | Google Scholar
B. Gugulothu, S. L. Sankar, S. Vijayakumar et al., “Analysis of wear behavior of AA5052 alloy composites by addition alumina with zirconium dioxide using the Taguchi–Grey relational method,” Advances in Materials Science and Engineering, vol. 2022, Article ID 4545531, 7 pages, 2022.
View at: Publisher Site | Google Scholar
V. Sivamaran, D. V. Balasubramanian, D. M. Gopalakrishnan, D. V. Viswabaskaran, D. A. G. Rao, and D. G. Sivakumar, “Mechanical and tribological properties of self-lubricating Al 6061 hybrid nano metal matrix composites reinforced by nSiC and MWCNTs,” Surfaces and Interfaces, vol. 21, Article ID 100781, 2020.
View at: Publisher Site | Google Scholar
G. B. V. Kumar, P. R., G. V. Chowdary et al., “Effects of addition of titanium diboride and graphite particulate reinforcements on physical, mechanical and tribological properties of Al6061 alloy based hybrid metal matrix composites,” Advances in Materials and Processing Technologies, vol. 8, no. 2, pp. 2259–2276, 2022.
View at: Publisher Site | Google Scholar
S. Teja Reddy, H. S. Manohar, and S. N. Anand, “Effect of carbon black nano-fillers on tribological properties of Al6061-aluminium metal matrix composites,” Materials Today: Proceedings, vol. 20, pp. 202–207, 2020.
View at: Publisher Site | Google Scholar
A. Kumar, R. C. Singh, and R. Chaudhary, “Investigation of nano-Al₂O₃ and micro-coconut shell ash (CSA) reinforced AA7075 hybrid metal-matrix composite using two-stage stir casting,” Arabian Journal for Science and Engineering, vol. 47, no. 12, pp. 15559–15573, 2022.
View at: Publisher Site | Google Scholar
H. A. Al-Salihi, A. A. Mahmood, and H. J. Alalkawi, “Mechanical and wear behavior of AA7075 aluminum matrix composites reinforced by Al₂O₃ nanoparticles,” Nanocomposites, vol. 5, no. 3, pp. 67–73, 2019.
View at: Publisher Site | Google Scholar
P. Maji, S. K. Ghosh, R. K. Nath, and R. Karmakar, “Microstructural, mechanical and wear characteristics of aluminum matrix composites fabricated by friction stir processing,” Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol. 42, no. 4, Article ID 191, 2020.
View at: Publisher Site | Google Scholar
I. Ogunrinola, M. Akinyemi, A. Aizebeokhai et al., “Silica and kaolin reinforced aluminum matrix composite for heat storage,” Reviews on Advanced Materials Science, vol. 62, no. 1, Article ID 20220305, 2023.
View at: Publisher Site | Google Scholar
T. Thirumalai, A. H. V. Reddy, S. Naga Kalyan, and R. Dhanasekaran, “Investigation of mechanical and wear characteristics of aluminum reinforced with quartz composites,” in Recent Trends in Mechanical Engineering, Lecture Notes in Mechanical Engineering, Springer, Singapore, 2020.
View at: Publisher Site | Google Scholar
S. Thirumalvalavan and N. Senthilkumar, “Evaluation of mechanical properties of aluminum alloy (LM25) reinforced with fused silica metal matrix composite,” Indian Journal of Engineering and Material Science, vol. 26, pp. 59–66, 2019.
View at: Google Scholar
S. Lyu, Y. Wang, H. Han et al., “Microstructure characterization and mechanical properties of Al-matrix composites reinforced by artificially-cultured diatom frustules,” Materials & Design, vol. 206, Article ID 109755, 2021.
View at: Publisher Site | Google Scholar
I. Sabry, M. A. Ghafaar, A.-H. I. Mourad, and A. H. Idrisi, “Stir casted SiC-Gr/Al6061 hybrid composite tribological and mechanical properties,” SN Applied Sciences, vol. 2, no. 5, Article ID 943, 2020.
View at: Publisher Site | Google Scholar
R. Vijayakumar, J. S. Srikantamurthy, S. Patil et al., “Optimization of wear process parameters of Al6061-zircon composites using Taguchi method,” Advances in Materials Science and Engineering, vol. 2023, Article ID 9507757, 10 pages, 2023.
View at: Publisher Site | Google Scholar
P. P. Ikubanni, M. Oki, A. A. Adeleke et al., “Tribological and physical properties of hybrid reinforced aluminum matrix composites,” Materials Today: Proceedings, vol. 46, pp. 5909–5913, 2021.
View at: Publisher Site | Google Scholar
D. S. Prasad, C. Shoba, and N. Ramanaiah, “Investigations on mechanical properties of aluminum hybrid composites,” Journal of Materials Research and Technology, vol. 3, no. 1, pp. 79–85, 2014.
View at: Publisher Site | Google Scholar
M. Kumar and A. Megalingam, “Tribological characterization of Al6061/alumina/graphite/redmud hybrid composite for brake rotor application,” Particulate Science and Technology, vol. 37, no. 3, pp. 261–274, 2019.
View at: Publisher Site | Google Scholar
A. Pattanaik, M. P. Satpathy, and S. C. Mishra, “Dry sliding wear behavior of epoxy fly ash composite with Taguchi optimization,” Engineering Science and Technology, an International Journal, vol. 19, no. 2, pp. 710–716, 2016.
View at: Publisher Site | Google Scholar
A. Kumar, R. S. Rana, R. Purohit, K. K. Saxena, J. Xu, and V. Malik, “Metallographic study and sliding wear optimization of nano Si3N4 reinforced high-strength Al metal matrix composites,” Lubricants, vol. 10, no. 9, Article ID 202, 2022.
View at: Publisher Site | Google Scholar
A. Baradeswaran, A. Elayaperumal, and R. F. Issac, “A statistical analysis of optimization of wear behavior of Al- Al₂O₃ composites using Taguchi technique,” Procedia Engineering, vol. 64, pp. 973–982, 2013.
View at: Publisher Site | Google Scholar
A. Dixit and K. J. Kumar, “Optimization of wear rate and coefficient of friction in silica gel reinforced aluminum metal matrix composites using Grey–Taguchi technique,” International Journal of Applied Engineering Research, vol. 10, pp. 10208–10212, 2015.
View at: Google Scholar
R. Siriyala, G. K. Alluru, R. M. R. Penmetsa, and M. Duraiselvam, “Application of Grey–Taguchi method for optimization of dry sliding wear properties of aluminum MMCs,” Frontiers of Mechanical Engineering, vol. 7, no. 3, pp. 279–287, 2012.
View at: Publisher Site | Google Scholar
J. Singh and A. Chauhan, “A review on sliding wear behavior of aluminum matrix composites with hybrid reinforcements for automotive applications,” Tribology Online, vol. 9, no. 3, pp. 121–134, 2014.
View at: Publisher Site | Google Scholar
S. Baskaran, V. Anandakrishnan, and M. Duraiselvam, “Investigations on dry sliding wear behavior of in situ casted AA7075-TiC metal matrix composites by using Taguchi technique,” Materials & Design, vol. 60, pp. 184–192, 2014.
View at: Publisher Site | Google Scholar
V. C. Uvaraja and N. Natarajan, “Optimization of friction and wear behavior in hybrid metal matrix composites using Taguchi technique,” Journal of Minerals and Materials Characterization and Engineering, vol. 11, no. 8, pp. 757–768, 2012.
View at: Publisher Site | Google Scholar

Copyright

Copyright © 2024 Dagim Tirfe et al. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

PDF Download Citation

Download other formats

Order printed copies

Views

461

Downloads

109

Citations