Indian Journal of Engineering & Materials Sciences

Vol. 18, August 2011, pp. 268-282

Influence of load and temperature on the dry sliding wear behavior of
aluminium-Ni
3
Al composites
Mehtap Demirel
a
& Mehtap Muratoglu
b
*
a
Vocational High School, Adiyaman University, 02040 Adiyaman, Turkey
b
Department of Metallurgy and Material Engineering, Engineering Faculty, Firat University, 23119 Elazig, Turkey
Received 31 May 2010; accepted 25 March 2011
The suitability of Ni
3
Al intermetallics as reinforcements for Al-base materials for tribological application has been
investigated. For this purpose, an Al/Ni
3
Al (5 wt%, 10 wt% and 15 wt%) composite is prepared by powder metallurgy
techniques and tested on a pin-on-ring apparatus. The effects of the applied load (83-150 N) and temperature (25-150C) at a
constant sliding velocity of 0.4 m/s on the wear behavior of Al-Ni
3
Al composites and wear mechanisms during dry sliding
are investigated. The worn surfaces are examined by scanning electron microscopy (SEM) and energy dispersive
spectrometry (EDS). It is found that the wear resistance of Al-Ni
3
Al composites decreased with increasing load and with an
increasing fraction of reinforcement Ni
3
Al particles. With an increasing fraction of Ni
3
Al particles, the wear resistance of
the composites increased at higher test temperatures, but not at lower test temperatures, and generally with increasing test
temperatures, the weight loss of composite materials increased slightly. It is also observed that a significant amount of
Fe-rich oxide particles become incorporated into the Al matrix during wear, forming a tribolayer.

Keywords: Metal matrix composites, Intermetallics, Tribology, Electron microscopy

Aluminium alloy matrix composites (AMCs)
reinforced with ceramics have been considered
suitable for a wide variety of applications
(i.e. automobile industry and marine structures). The
tribological characteristics of AMCs reinforced with
ceramics have been extensively investigated to
determine the effect of different combinations of
matrix alloy and reinforcements on wear behavior
1-4
.
The resultant matrix/reinforcement bonding in these
AMCs is often undesirable as it may induce reduced
ductility and fracture toughness. Thus, the
introduction of new reinforcements is being
investigated
5,6
.
A large number of Al-base composites reinforced
with Ni-base intermetallics are being developed for
high performance materials in aerospace applications;
NiAl has been considered as a potential reinforcement
capable of increasing wear resistance for die-cast Al
alloys
5
. More recently, it was found that Ni
3
Al
particles improve the resistance of Al matrices
7
.
Strafellini et al.
8
proposed that friction materials are
receiving particular attention because of the possibility
of using these materials for disc brakes in automotive
applications. AMC discs offer promising advantages,
such as lower density and higher thermal conductivity.
Varin et al.
9
studied AMCs reinforced with
intermetallic ribbons and concluded that they might
be appropriate for high temperature applications,
particularly when the intermetallic is Ni
3
Al-based.
One of the most important advantages of employing
Ni
3
Al as a reinforcement can be inferred from the fact
that its thermal expansion coefficient at room
temperature, 13 10
-6
K
-1
, is much closer to that of Al
alloys
10,11
, 18 to 24 10
-6
K
-1
, when compared to
those of ceramic reinforcements, for example,
3.3 10
-6
K
-1
for SiC
12
. This small difference in the
thermal expansion coefficient will lower residual
stresses that appear at reinforcement matrix interfaces
while exposing the composite to thermal cycles
7
.
Al/Ni3Al composites reduce ductility because the
interface between the reinforcement and the matrix is
altered by diffusion reaction products12. Martin
et al.
13
analyzed the wear behavior of AMCs in the
case of external heating at temperatures ranging up to
200C. It was found that wear increased as
temperature increased due to thermal softening of the
composite, and became severe at a critical
temperature
8,13
. However, Wang et al.
3
found that the
enhanced high temperature behavior of the composite
________________________
*Corresponding author (E-mail: mehtapmuratoglu@hotmail.com)
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3
Al COMPOSITES


269
will promote better deformation resistance at high
wear loads and speeds than unreinforced Al.
Al-based MMCs reinforced with intermetallics
were first proposed by Yamadi and Unakoshi
14
. Later,
Ruutopold et al.
15
suggested that Ni
3
Al would be an
optimum intermetallic reinforcement, but observed
extensive reaction between the intermetallic and the
matrix when composites were produced via the
casting route. In the experimental results, it was
determined that increasing drill hardness and feed
rates decreased the surface roughness of the drilled
surface for all heat-treated conditions
14,15
. Izciler
et al.
16
used the rwat to characterize the low-stress
abrasive wear behavior of 2124 Al alloy composite.
SiC and Al
2
O
3
abrasive particles were used as the
abrasive medium. It was found that the wear rate of
the composites was increased by increasing the load
wear rate of the composites; those abraded by SiC
abrasive particles showed higher values than those of
the composites abraded by Al
2
O
3
abrasive particles
16
.
In the present work, for a meaningful
understanding of the role of the Ni
3
Al intermetallic
particles in the wear behavior of composites, the use
of Ni
3
Al as a wear resistance reinforcement for Al-
based composites was investigated. The main
objective of this work is to compere the effects of the
load and the temperature together with the weight
percentage of the reinforcement on dry silding wear
behaviour of the that composites.

Experimental Procedure
Materials
Commercial Al powder supplied by ALPACO
(Aluminium Powder Company) of average size 70 m
was employed as the matrix, and Ni
3
Al particles
supplied by Alfa (USA) with a mean particle size of
<149 m were used as the reinforcements. The SEM
micrograph of the Ni
3
Al particles is shown in Fig. 1.
The particle-reinforced composites contained 5, 10
and 15 wt% Ni
3
Al were fabricated by powder
metallurgy (PM) techniques. The powders were mixed
for 30 min in a stainless steel cup. After mixing, the
powder mixtures were uniaxially cold pressed at
350 MPa and sintered at 500C for 45 min in an Ar
which has 99.9% purity atmosphere. Vacuum degree is
110-3 Pa. The dimensions of the cylindrical specimens
were a diameter of 12 mm and a height of 7.5 mm.
Friction and wear tests


Fig. 1Scanning electron micrograph of the Ni
3
Al particles
INDIAN J. ENG. MATER. SCI., AUGUST 2011


270
Sliding wear and friction tests were performed on a
pin-on-ring apparatus with the composite specimen
serving as the pin under dry conditions. A schematic
diagram of the experimental arrangement is shown in
Fig. 2. The dry sliding wear tests were carried out at a
constant sliding velocity of 0.4 m/s within an applied
normal load range of 83-150 N and a normal
temperature range of 25-150C. Steel rings with a
diameter of 35 mm were used as the counterface. The
counterparts in the experiments were fabricated from
GCr15 steel. Prior to the tests, the contact surfaces of
the composite specimens were polished using 600-,
800-, 1000- and 1200- grit SiC emery paper in
running water. Specimens and rings, ultrasonically
cleaned and washed in acetone, were weighed to the
nearest 0.1 mg using an electronic analytical balance
before and after each wear test. The results were taken
as the average from three tests. The coefficients of
friction were obtained periodically by measuring the
tangential force on the specimen using a strain gauge
bridge. The microstructures of the specimens were
examined by scanning electron microscopy (SEM)
and energy dispersive microanalysis (EDS).
Results and Discussion
Microstructure and hardness
The SEM micrographs in Fig. 3 illustrates the
typical microstructure of Al- 10 wt% Ni
3
Al
composite specimen prepared by powder metallurgy
techniques. The composite showed Ni3Al particles
uniformly distributed throughout the Al matrix and
signs of low porosity. Bulk hardness measurements
were made using a Brinell hardness tester with a
contact pressure of 15 gr. The results of the hardness
test on the composites are given in Table 1. The
hardness values of the composites are much higher
than that of the unreinforced Al matrix and clearly
increase with Ni
3
Al weight percentage. And also
XRD pattern of the compacted Al composite samples
(Al- 10 wt% Ni
3
Al) after sintering are given in


Fig. 2 Schematic diagram of pin-on-ring apparatus


Fig. 3 Scanning electron micrograph of the Al-10 wt% Ni
3
Al composite specimen
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3
Al COMPOSITES


271
Fig. 4. This shows that aluminum oxides observed
on composite samples after sintering althoug
sintering was made in controlled atmosphere.
Relationships between weight loss and load
The relationship between weight loss and load for
various reinforcement (Ni
3
Al) amount within the
sliding distance of 1500 m are given in Fig. 5. Weight
losses of these materials increase linearly with
increasing load. The wear behavior could lead to the
conclusion that Ni
3
Al particles improve the wear
resistance of pure Al in the load range investigated, as
the weight loss of the composite specimens were lower
than those of the Al specimens. For the composites
investigated, the wear resistance of the composite
decreases with increasing Ni
3
Al weight percentage.
Table 1 Hardness of the unreinforced Al matrix and
Al-Ni
3
Al composite specimens at ambient temperature
Specimen Average hardness HB
Al 36
Al-5 wt.%Ni
3
Al 55
Al-10wt.%Ni
3
Al 57
Al-15wt.%Ni
3
Al 60

Fig. 4 XRD pattern of the compacted Al-10 wt% Ni
3
Al composite samples after sintering















Fig. 5 The variation of weight loss as a function of load for Al/Ni
3
Al composites and unreinforced Al at ambient temperatue
INDIAN J. ENG. MATER. SCI., AUGUST 2011


272




















(a)

(b)
Fig. 6 Scanning electron micrographs of worn surface of the Al-15 wt% Ni
3
Al composite specimen for (a) 83 N and (b) 150 N, at
ambient temperatue (P: zones with creaters and G: zones with grooves, arrow indicates sliding direction)
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273
The presence of Ni
3
Al particles is also useful in
preventing the aluminium matrix from early fracture
because the particles can maintain the specimens
structural integrity. However, increasing the weight
percentage of Ni
3
Al particulate at increasing loads
tends to increase the weight loss of the composites.
Particulate resulted in a reduction in the extent of
plastic deformation of the matrix, and increasing the
load tends to cause extensive plastic deformation of
the matrix and crack nucleation at the particle-matrix
interface, which can cause particle decohesion
17
. Due
to the occurrence of work-hardening of the plastic
deformation in the subsurface materials, cracks
nucleated around the reinforcement particulate. Under
repeated loading and deformation, the cracks
propagated in the matrix. Eventually, the propagating
cracks joined together, causing particles to pull out
17
.
When the load is increased to reach the fracture
strength of the particle, the particles began to fracture
and lose their ability to support the load. For particle-
reinforced composites, the particles near the contact
surface may more readily induce the nucleation of
cracks due to the interface debonding between the
particles and the matrix in comparison to unreinforced
Al. In the sliding wear process, these cracks may
propagate and connect to form subsurface cracks; the
subsurface damage process is increased by the
presence of particles
18
.
Figures 6(a) and (b) show SEM images of wear
tracks of Al- 15 wt% Ni
3
Al composites at different
loads (83 N and 150 N). Wear tracks on Al/Ni
3
Al
composite material surfaces consisted of zones with
elongated craters in the sliding direction together with
smooth zones with longitudinal grooves. At 83 N,
narrow areas with long grooves and large areas with
small craters were present. Increasing the load to
150 N resulted in an increase in large areas of long
grooves together with lengthened craters; the number
of craters increased with increasing magnitude of the
applied load on the worn surface. The worn surface
was characterized by wide grooves progressed with
high plastic deformation, and there was also
fragmentation with material displaced to the sides of
the wear grooves. Figure 6b also showed the worn
surface of the composites indicated high weight losses
between composite specimens. Related to this
observation, taken surface roughnees measurement
was given in Table 2. Al- 15 wt% Ni
3
Al composite
specimen worn at 150 N showed the highest surface
roughnees value between composite specimens. The
wear surface of a Al-5 wt% Ni3Al specimen shown in
Fig. 7a was smoother than that of the Al-15 wt%
Ni
3
Al composite. In addition, worn surfaces of Al-5
wt% Ni
3
Al showed a decrease in craters while the
number of large grooves increased. Figure 7b shows
SEM images of the worn unreinforced Al surface at
150 N. The appearance of the worn composite surface
was different from that of the unreinforced matrix at
150 N. The wear surface of unreinforced Al exhibited
large areas with long grooves and craters with
adhesion in the sliding direction. So, it showed the
highest weight loss at 150 N for the all test specimens.
Figures 8(a) and (b) show EDS results of the worn
surface of Al-15 wt% Ni
3
Al tested at 83 N and 150 N.
For both loads, the EDS spectra indicated that the
composite materials contained Al, Fe, Ni and O. The
higher intensity of Fe indicates the transfer of
counterface materials to the surface of a Ni
3
Al/Al
composite, and the concentration of Ni shows that
worn Ni
3
Al fragments spread onto the surface. An Al-,
Fe- and O- was present in both materials, but in much
greater quantities at the highest load. The
concentration of Ni decreased together with
increasing load; this result showed that deformed
Ni
3
Al could not abrade the worn surface and Ni
3
Al
particles have fewer chemical interactions with the
counterface19. The reason for the superior wear
resistance of the composite at 150 N was believed to
be the interaction with the counterface. The true
contact areas of the composites were smaller than that
of the unreinforced matrix, and the chemical
interactions with the counterfaces of the composites
were less than that of the unreinforced matrix.
Wear products coming either from the counterface
(Fe-rich oxides) or the worn surface itself penetrate
the soft Al matrix. This leads to the formation of a
mechanically mixed tribolayer (MML) basically made
up of oxide particles and Al
27,19
. The wear surface
shows the predominant mode at the lower
load (large areas with craters) and changes to a
Table 2 Surface roughness parameters of the test specimens
for the load
Surface Roughness (Ry)
Load Al
matrix
Al-5 wt%
Ni
3
Al
Al-10 wt%
Ni
3
Al
Al-15 wt%
Ni
3
Al
83 2.62 2.29 2.46 2.6
100 2.65 2.3 2.64 2.73
150 2.85 2.35 2.74 2.8
INDIAN J. ENG. MATER. SCI., AUGUST 2011


274

(a)

(b)
Fig. 7 Scanning electron micrographs of worn surfaces of the (a) Al-5 wt% Ni
3
Al composite specimen tested at 150 N and
(b) unreinforced Al specimen tested at 150 N, for ambient temperature (arrow indicates sliding direction)
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3
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275


(a)

(b)
Fig. 8 EDS spectra of large scanned areas of the worn surface of Al-15 wt% Ni
3
Al composite specimen tested at (a) 83 N and
(b) 150 N
INDIAN J. ENG. MATER. SCI., AUGUST 2011


276
predominantly abrasive mode at the higher loads (large
smooth areas with long grooves). In addition, the
transfer of Fe from the counterface applied pressure to
the matrix; severe plastic deformation was observed in
the matrix around these Fe particles. The total depth of
severe deformation in other areas of the matrix was not
large
20
. This situation results in weight loss of all
specimens that increased with increasig load.
The results of the coefficient of friction of
unreinforced Al and the composites with different
applied loads at a constant temperature of 25C are
given in Table 3. The coefficient of friction of the
composites is lower than that of the unreinforced Al
matrix and clearly increases with increasing Ni3Al
weight percentage especially at high loads (100 N and
150 N). The coefficient of friction for all materials
increased with increasing load. This result is in good
agrement with the results reported in the
literatures
19,21
. The variations in the reported results
and the present results can be taken nearly constant
for the friction coefficient after 100 N. In fact, the
friction coefficient is in general determined by two
contributions; the first due to the adhesive interaction
between the contacting asperities and the second
related to the ploughing contribution due to
abrasion
21
. At high loads, the contribution of adhesion
increases in importance because its greater hardness
reduces the contribution of abrasion, and the friction
cofficient increases with load because of the increase
in the real area of contact.

Relationships between weight loss and temperature
The effect of applied temperature on the friction
and wear behavior of Al/Ni3Al composites was
studied by varying the temperature in the range from
25C to 150C at a constant load of 83 N. The
variation in the weight loss of the composites and in
the coefficient of friction with applied temperature are
plotted in Figs 9(a) and (b), respectively. The weight

(a)


(b)
Fig.9 The variation of (a) weight loss and (b) coefficients of friction of the Al-Ni
3
Al composite specimens tested at 83 N as a function
of the test temperatures
DEMIREL & MURATOGLU: DRY SLIDING WEAR BEHAVIOR OF ALUMINIUM-Ni
3
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277
loss of unreinforced Al increased with increasing
temperature. For composites, the effect of the
reinforcement was strengthened with increasing
temperature, and the weight loss for composite
materials with increased amounts of Ni
3
Al particles
was lower with increasing temperature. In addition,
the weight loss of the composites was generally lower
than that of unreinforced Al. It is evident that the
coefficients of friction for the composites were lower
than those for the unreinforced Al matrix. Also with
an increasing weight percentage of Ni3Al particulate,
the coefficient of friction for the composite slightly
decreased. And also one of the most important
advantages of employing Ni
3
Al as a reinforcement
can be inferred from the fact that its thermal
expansion coefficient, 13 10-6 K
-1
, is much closer to
that of Al alloys10,11, 18 to 24 10-6 K
-1
. This small
difference in the thermal expansion coefficient will
lower residual stresses that appear at
reinforcement/matrix interfaces while exposing the
composite to thermal cycles. A lower degree of failure
originated at the particle/matrix interface can,
therefore, be expected. In addition, a high thermal
stability of Ni3Al in an aluminum matrix was
observed after long-term annealing at 300C
12
makes
this intermetallic an advantageous reinforcement for a
wear-resistant composites. The enhanced high
temperature behaviour of the composite will promote
better deformation resistance at high temperature than
unreinforced Al.
The SEM micrographs of the worn surface of the
specimens presented in Fig. 10. It shows that wear
mechanisms involving plastic deformation, cracking
and pulling out of particles occured at a wear
temperature of 150C. Wear in the composite is
proceeded by the mechanism already observed at
ambient temperature for load tests. Wear tracks on all
specimen surfaces occurred from craters together
with grooves in the sliding direction. However, these
microstructures appear in different dimensions, sizes
and shapes under different wear conditions. Effects of
the weight percentage on the wear surface of the
composites were more pronounced. Figure 10a shows
the SEM micrograph of worn surface of the
unreinforced Al specimen at 150C. This surface
showed predominantly adhesive mode at the high
temperature. Crack formation was produced by the
extremely high strains induced in the matrix by the
pressure of the steel counterface, which were
amplified as the matrix became softer because of the
thermal softening and recrytallization at elevated
temperature
21
, and by the development of adhesive
forces between the two bodies in contact. These
adhesive forces were responsible for the chunks of
material glued to the steel sphere after high
temperature testing. Because of the high hardness and
low weight loss of the Ni
3
Al particles in the
composites, these particles very effectively resist
penetration and cutting into the surface. For
composites, the softer matrix around the particulate
was fractured under both load and temperature.
Contact surfaces arose between the steel and the
Ni
3
Al particle
21
. Ni
3
Al particles were fractured and
became fragmented (Fig. 10(b)-(d)).
The effect of temperature and weight percentage
on the wear surface of the composites were more
pronounced. The SEM micrographs of the worn
surface of the Al-15 wt% Ni
3
Al composite tested at
50C is shown in Fig. 11. For 50C, wear was by
abrasion and adhesion and the friction coefficient was
quite high. The results showed that the Al-15 wt%
Ni
3
Al composite tested at 150C indicated to have a
better worn surface than that of at 50C. While the Al-
15 wt% Ni
3
Al composite showed large areas with
long craters, its grooves seemed to increase and there
were cracks on the wear surface. For 150C
(see Fig. 10d), smooth areas with long grooves
increased, but small craters lengthened and their
number decreased. The EDS analysis (Fig.12)
performed on wear tracks of Al-15 wt% Ni3Al
composite for 50C and 150C is indicated that an Al-
Fe which obviously transferred from the counterface,
-O- containing nanocrystalline phase was present in
both materials, but in much greater quantities in the
specimens tested for 150C. A mechanically mixed
surface layer (MML)
8,22
was present for both
materials at all temperature like as for load tests. All
surfaces contained an MML to some degree, which
would also be expected to have higher stiffness and
Table 3 The coefficient of friction obtained according to the
applied loads for the unreinforced Al matrix and Al-Ni
3
Al
composite specimens at ambient temperature

Coefficient of friction
Load Al Al-5 wt%
Ni
3
Al
Al-10 wt%
Ni
3
Al
Al-15 wt%
Ni
3
Al
83 0.16 0.15 0.15 0.15
100 0.25 0.24 0.25 0.25
150 0.26 0.24 0.26 0.26
INDIAN J. ENG. MATER. SCI., AUGUST 2011


278


(a)

(b)
Fig.10 (a,b) Scanning electron micrographs of worn surfaces of the (a) unreinforced Al specimen, (b) Al-5 wt% Ni
3
Al composite specimen
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3
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279

(c)

(d)
Fig.10 (c,d) Scanning electron micrographs of worn surfaces of the (c) Al-10 wt% Ni
3
Al composite specimen and (d) Al-15 wt%
Ni
3
Al composite specimen, tested at 150C (arrow indicates sliding direction)
INDIAN J. ENG. MATER. SCI., AUGUST 2011


280



Fig.11 Scanning electron micrographs of worn surface of the Al-15 wt% Ni
3
Al composite specimen tested at 50C
(C: zones with creaters and G: zones with grooves, arrow indicates sliding direction)


(a)
Fig.12 (a) EDS spectra of large scanned areas of worn surface of the Al-15 wt% Ni
3
Al composite specimen tested at 50C
DEMIREL & MURATOGLU: DRY SLIDING WEAR BEHAVIOR OF ALUMINIUM-Ni
3
Al COMPOSITES


281
flow stress than the substrate and should therefore
have influenced the true contact area. As can be
observed, the Fe and O content increased together
with increasing temperature, however the
concentrations of Ni decreased because of the
decreasing broken amount of Ni
3
Al reinforcement.
Interestingly, 150C showed less weight loss than
50C. The result showed that this transfer layer may
acted as a solid lubricant, and the effect of this layer
was more pronounced together with increasing
temperature. The surface of specimens for high
temperature was protected by this layer and also
decreases the friction coefficient (see Fig. 10b).
Interestingly, the presence of an MML is largely
ignored in the classical theories of wear. But, It was
recognised that MMLs play a significant role in dry
sliding wear of material in this study.

Conclusions
The following conclusions can be drawn from this
study:
(i) The effect of the weight percentage of Ni
3
Al
particulate on the sliding wear resistance of the
composites varied with the load. Though the
wear resistances of the composites were higher
than that of the unreinforced matrix, the wear
resistance of the composites decreased with
increasing weight percentages of Ni
3
Al.
(ii) In wear experiments carried out at different
temperatures, weight loss of both the
unreinforced matrix and lower percentage
reinforced composites (5 wt% and 10 wt%)
increased with increasing temperature. But
also, the weight loss of higher percentage
reinforced composite (15 wt%) was decreased
at higher temperatures (100C and 150C).
(iii) Some amount of Fe (from the counterfaces)
was incorporated into the Al matrix. The Fe
content increasing with load and temperature.
Ni
3
Al particles limited the penetration of
oxide particles, which protected the matrix.
According to EDS analysis, a mechanically
mixed surface layer (MML) was present for
all materials at all loads and all temperatures,
the effect of which increased approximately
linearly with load and temperature. MML
contained appreciable quantities of Fe for
high temperature and high weight percentage
of the Ni
3
Al.
(iv) In this work, the coefficients of friction for
the composites were approximately
independent of the load and the temperature.
The coefficients of friction for the composites
were lower than that for the unreinforced
matrix under both load and temperature.
However, although the coefficients of friction


Fig.12 (b) EDS spectra of large scanned areas of worn surface of the Al-15 wt% Ni
3
Al composite specimen tested at 150C
INDIAN J. ENG. MATER. SCI., AUGUST 2011


282
for the composites increased with increasing
weight percentages of Ni
3
Al particulate at
different loads, they decreased with
increasing weight percentages of Ni
3
Al
particulate at different temperatures.

Acknowledgements
The authors would like to acknowledge the Frat
University Research Fund (FUBAP-1209) for
financial support throughout this study.

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