Materials Today: Proceedings xxx (xxxx) xxx

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Materials Today: Proceedings

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A study on wear assessment of AA6061-B4C-Nanographite hybrid

composite
K. Rajkumar a,⇑, K. Ramraji a, K.M. Nambiraj a, A. Gnanavelbabu b
a
Department of Mechanical Engineering, SSN College of Engineering, Chennai 603110, India
b
Department of Industrial Engineering CEG Campus, Anna University, Chennai, TN 600 025, India

a r t i c l e i n f o a b s t r a c t

Article history: Wear performance of aluminium metal matrix composites have reached essential research studies for the
Received 26 September 2019 application of tribo components or products. This research paper aims to fabricate the aluminum alloy
Received in revised form 9 November 2019 composite with various combinations of Nano Graphite (NG) and boron carbide particles and select a rel-
Accepted 13 November 2019
atively superior wear resistance composite in relation to the wear rate and surface characteristics. A two-
Available online xxxx
step stir casting method was adopted for the production of AA6061-B4C-nanographite hybrid composites.
Wear performance of fabricated composites were tested in a pin-on-disc tribometer with consideration of
Keywords:
constant parameter of sliding distance, speed, and normal load. Experiment results showed that a com-
Boron carbide
Nanographite
bination of 10 vol% of nanographite and boron carbide particles exhibited a superior wear performance
Wear due to the synergetic effect of both particles existed at the contact zone. These developed materials will
Tribolayer be used in brake pad, automotive brake rotor, and sliding member of light machine tools.
Surface roughness Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the First International con-
ference on Advanced Lightweight Materials and Structures.

1. Introduction
Aluminium metal matrix composites (AMMCs) is one of the
revalued engineering materials and generally used to design the
structural and tribological components for the aircraft and auto-
motive application. This is specifically showing a lightweight
weight, higher strength, superior wear resistance, and low thermal
resistance. An improvement of friction and wear properties of
Metal Matrix Composites (MMCs) is constantly taking place with
the discovering of nano particles specifically nano crystalline car-
bon particles [1–3]. But a superior mechanical and tribological
properties of MMC can be realized by the addition of ceramic par-
ticulate reinforcement.
A B4C reinforcement particle is a versatile nature in offering the
best mechanical and nuclear absorbing properties. Moreover, its
strength just rated below the diamond but almost reaching the
highest value. In the view of imparting a better wear resistance
to the composite, boron carbide is an excellent choice due to rela-
tively higher hardness. Boron carbide is the form of reinforcement
for the composite becomes inevitable especially in nuclear applica-
⇑ Corresponding author.
E-mail address: rajkumark@ssn.edu.in (K. Rajkumar).
tion since its ability to absorb neutron very well. In fact, mono rein-
forcement does not satisfy application requirements or may need
to compromise on its some of the physical and mechanical proper-
ties [4]. Tribological component materials are commonly made-up
with a combination of hard reinforcement and solid lubricant par-
ticles, also known as hybrid composite. [5]. Shorowordi et al. [6]
studied three different types of reinforcement particles such as
B4C, SiC and Al2O3 in the aluminium metal matrix composites,
and manufactured with the stir-casting followed by hot extrusion
method. They reported that the B4C-particle reinforced Al-
composite revealed better interfacial bonding compared to the
other two composites. Chen et al. [7] and Zhan-Zhang [8] described
the addition of self-lubricating particles like graphite in the alu-
minum matrix is providing a better tribo performance. Graphite
solid lubricant greatly increases antifriction properties because of
its easy sliding nature with low shear force. Abenojar et al. [9]
stressed a need for self-lubricating material with graphite particles
for replacing the lead alloyed aluminium based metal matrix con-
tact material which is very harmful to nature. Besides graphite has
improved the machinability of composites. But a consequence is
present when using graphite particles as a solid lubricant, it
reduces the strength and fracture toughness of material [10]. A
substantial decrease in the strength of the matrix by graphite

https://doi.org/10.1016/j.matpr.2019.11.151
2214-7853/Ó 2019 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the First International conference on Advanced Lightweight Materials and Structures.

Please cite this article as: K. Rajkumar, K. Ramraji, K. M. Nambiraj et al., A study on wear assessment of AA6061-B4C-Nanographite hybrid composite, Mate-
rials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.151
2 K. Rajkumar et al. / Materials Today: Proceedings xxx (xxxx) xxx
particles can be increased with boron carbide particulate
reinforcement.
Tang et al. [11] investigated the relative importance of 5 and
10 wt% B4C particles in the aluminum matrix. A higher 10 wt%
composite showed a higher wear resistance with an outstanding
improvement of 40% when compared to the 5 wt% B4C composites.
Generally aluminum virgin alloy showing high wear due to the
poorest strength and plastic deformation during the dry sliding
but a ceramic reinforcement like SiC changing matrix strength
and contact behavior by forming a mechanical mixed tribo layer
[12]. Riahi and Alpas [13] proved the mechanical mixed tribo layer
has reduced friction and wear of MMC. Baradeswaran et al. [14]
have compared the wear performance of AA6061 alloy and
AA7075 reinforced with boron carbide-graphite. It is observed that
AA7075 was superior in wear performance than that of AA6061.
Monikandan et al. [15] studied the tribological behavior AA6061-
B4C composites by liquid metallurgy-processed. It is found that
the combination of abrasion, delamination and adhesion wear
mechanisms were operating at all sliding conditions. These are
controlled by B4C particles, speed, applied load, and sliding dis-
tance. Moreover, they studied the friction coefficient and wear
which are increase with increasing in applied load.
Elayaperumal and Baradeswaran [16] studied the effect on
mechanical properties by the addition of graphite in AA7075. They
observed that ultimate tensile strength reduces with an accumula-
tion of graphite particles since the graphite particle has shown a
brittle nature. Estrada-Guel et al. [17] investigated the dispersion
of nano-graphite in AA7075 using a mechanical alloying method.
They found that a higher volume fraction sample shows a poor
mechanical strength due to poor interface contact between matrix
alloy and reinforcement particles. Kok [18] suggested a conven-
tional stir casting technique is relatively best for low-cost produc-
tion and gives a good bonding between aluminium alloy and
reinforcement particles. It is considering from the above literature
an urgent need to investigate the synergetic effect of graphite
nanoparticles and hard boron carbide reinforced aluminum alloy.
Hence this research paper focuses on the fabrication and wear per-
formance of Al-boron carbide and nanographite hybrid composites.
2. Experimental details
2.1. Metal matrix composite fabrication
A two-step stir casting method was adopted for the production
of hybrid composites. To fabricate the composite material, the base
aluminium 6061 alloy matrix was used. The scrap form of AA6061
alloy was used to melt in a graphite crucible. Prior to adding the
reinforcement particles, graphite and B4C particles are preheated.
The percentage of nano-graphite and B4C were varied from 5 to
15% by a step of 5% increment. Aluminium was melted at 850 °C
and allowed to cool to 760 °C and then preheated particles were
added manually. The stirring of particles along with the slurry
stage of aluminum matrix was done. Again, the slurry of aluminum
melt was heated to 800 °C and stirrer speed was maintained
700 rpm for approximately 5 min. This mechanical stirring action
distributes the reinforcement’s particles evenly in aluminum melt.
The same procedure was adopted for manufacturing all concentra-
tions of NG and boron carbide reinforced hybrid composites. After
that solution heat treatment of T6 was done to improve the
strength of hybrid composites. Fabricated composites were heated
to 520 °C in a resistance furnace and maintained the same temper-
ature for 1 h and then water quenched at room temperature. Then
artificial aging of composite done with heating to 250 °C and main-
tained for 5hrs and it allowed cooling in an open atmospheric con-
Please cite this article as: K. Rajkumar, K. Ramraji, K. M. Nambiraj et al., A study on wear assessment of AA6061-B4C-Nanographite hybrid composite, Mate-
rials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.151
dition. The density of the composites was determined using an
Archimedes principle.
2.2. Tribology test
Tribo behavior of hybrid campsites was evaluated through the
Pin-on-disc tribometer under elevated temperatures and con-
trolled humidification conditions. The conducted tribo experi-
ments were in line with the ASTM G99 standard. Fabricated
composites were machined to pin cylindrical form of diameter
8 mm and height 50 mm. Pin surface was grounded with 1000
grade SiC paper followed cleaning with acetone. The pin just posi-
tioned perpendicular to the disk steel surface which has EN 30-
63HRC hardness. The tribo experiments were done with parame-
ters of sliding speed of 1.4 m/s, a normal load of 25 N and a sliding
distance of 1000 m and a temperature of 150 °C. Pin heating is
done by a resistance heating coil setup which mounted on the
periphery of the pin surface. The mass loss of pin after wear testing
was found from an electronic balance with an accuracy of 0.0001 g.
Mass loss was converted into a volumetric wear rate.
2.3. Non-contact roughness test
Surface Roughness measurement of the uneven surface pro-
duced after the sliding wear test was done. The surface roughness
value of the worn surface is one of indicator for the tribo perfor-
mances. Non-contact roughness test was used in this analysis to
check whether the parameter chosen has a significant impact on
the surface of the composite or not. This analyze was carried out
in Taylor-Hobson precision’s TALYSURF CCI LITE tester using
Coherence Correlation Interferometry as a measurement
technique.
2.4. Microstructural analysis
Scanning Electron Microscopy (SEM) was used to reveal the sur-
face characteristic and surface topography of the worn surface. To
understand the impact of parameter chosen and surface character-
istics of the worn surface after wear testing, the composition of
composite which showing a minimum and maximum wear condi-
tion only performed.
3. Results and discussion
3.1. Microstructural and chemical analysis
Table 1 shows the density of fabricated composites. The density
of composites decreases with increasing boron carbide and nano-
graphite particle addition.
Fig. 1 shows the wear rate of nano graphite composites with dif-
ferent concentrations of boron carbide. It can be seen that wear
rate is more related to the boron carbide amount. The wear resis-
Table 1
Properties of composites.
Nano-graphite Vol.% AA6061-B4C Density gm/cm3
5 90-5 2.626
85-10 2.458
80-15 2.380
10 85-5 2.416
80-10 2.510
75-15 2.440
15 80-5 2.356
75-10 2.332
70-15 2.271
 K. Rajkumar et al. / Materials Today: Proceedings xxx (xxxx) xxx 3

NG 5 vol% composite produces insufficient lubricating tribo layer

that could not capable to cover the entire worn surface. This result
of low-level solid lubricant presence in the composite would form
the isolated batches of a thin compact tribo layer on the sliding
surface. This leads to partial metal–metal contact increases the
wear rate of composite.
The lubricating layer thickness is observed to be increasing with
the increased amount of NG in aluminum matrix. Furthermore,
more amount of NG (10 vol%) particle presence in composites
tends to form a continuous tribo layer. This certainly reduced
direct metal contact and also ensured smooth sliding between
the surfaces which reduce the wear rate of composite. Moreover,
an increase in NG particles, beyond 10 vol%, agglomeration of NG
particles in aluminum matrix leads to a poor mechanical property.
This considerably increased the wear rate of 15 vol% NG composite.

3.2. Microstructural analysis

Fig. 1. Wear rate vs volume fraction of NG.
tance increases with the increase of boron carbide particles in the
metal matrix. This is due to dislocations pinned down by ceramic
particles. However, the mutual effect of NG with boron carbide is
not realized at 15 vol% boron carbide. This could because of an
increase in wear rate at 15 vol% boron carbide with 15 vol% NG.
Fig. 2(a, b) shows SEM micrographs of 10%NG and 15%NG–B4C
composites. These SEM images revealing the presence of graphite
nano particles, and also these images are at high magnification
so that the boron carbide particles are not clearly observed. But
there is some porous site that can be seen from these images. Apart
from that, the microstructure shows free from crack and fissures.
Fig. 3. show the major elements of alloy elements and carbon peak
of nanographite.

Fig. 2. (a,b). SEM surface of 10%NG and 15%NG composites.

Fig. 3. EDX of typical composite.

Please cite this article as: K. Rajkumar, K. Ramraji, K. M. Nambiraj et al., A study on wear assessment of AA6061-B4C-Nanographite hybrid composite, Mate-
rials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.151
4 K. Rajkumar et al. / Materials Today: Proceedings xxx (xxxx) xxx

Fig. 4. Worn surface of Al 90-Boron carbide 5-NG 5. Fig. 6. Worn surface of Al 80-Boron carbide 5-NG 15.

SEM images from the worn surfaces of different concentrations
of NG and boron carbide composites were used to identify the
operating wear mechanism under elevated temperature sliding
conditions. Fig. 4 shows an SEM image of 5 vol% NG composite. It
shows that there are many plastic grooves with rarely found of
tribo lubricating layer. This SEM image also confirms a low level
of lubricating behavior. The scarcity in lubrication at contact sur-
face increases the plastic deformation of pin surface. Also, the hard
asperities of counter surface abraded the pin surface. As in 10% NG,
the contact conditions have been changed by extrusion of graphite
particles to surfaces. This makes the continuous tribo intermediate
layer spreading across the pin surface. This tendency increases
with increasing of NG amount. This was evident from SEM images
of the worn surface, as shown in Fig. 5 (a, b). These SEM images
show a continuous tribo layer formation and slim grove lines on
the contact surfaces. This indicated that a low level of wear rate
of 10 vol% NG composite.
Further an increasing in nanographite beyond 10 vol% in the
composite results an agglomeration of nano particles. This leads
to a fracture in the metal matrix under the normal load, in turn,
increased wear rate. This finding can clearly support by SEM image
as shown in Fig. 6. In this SEM image, the worn surface shows a fac-
ture of metal matrix substrate where agglomerated NG particles
are stress concentration sites.
3.3. Roughness analysis
Fig. 7 (a, b) shows the roughness plot of the before the wear
tested composite pin. This plot clearly shows a moderate uneven
surface of the composite pin due to abrasive action by 1000 grade
SiC paper while polishing. It is surface roughness value Ra is
2.26 mm. Fig. 8 (a, b) shows the roughness plot of the wear tested
composite pin. It shows the regular even surface in the worn sur-
face as a result of the formation smooth tribo layer. Its surface
roughness value Ra is 1.03 mm. This tribo layer eventually fills

Fig. 5. (a,b). Worn surface of Al 80-Boron carbide 10-NG 10.

Please cite this article as: K. Rajkumar, K. Ramraji, K. M. Nambiraj et al., A study on wear assessment of AA6061-B4C-Nanographite hybrid composite, Mate-
rials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.151
 K. Rajkumar et al. / Materials Today: Proceedings xxx (xxxx) xxx
Fig. 7. (a, b). Before wear testing 75-10-15.
Fig. 8. (a, b). Wear tested 75-10-15.
the valleys and between the peak of the asperities [19]. This pro-
cess results in a smoother worn surface since tribo layer formation
is a steady-state process. Finally, it could reduce the friction effect
thereby declining of wear of composite surface.
4. Conclusions
Wear performance of AA6061-boron carbide-Nanographite
composites is a function of reinforcement’s concentration and their
mutual cooperative effect while sliding was studied and the fol-
lowing conclusions were drawn.
 NG (5 vol%) is insufficient to produce a lubricating tribo layer
and not effectively cover the contact surface.
 NG (10 vol%) exhibits the lowest wear rate since the composite
contact zone is fully covered with the tribo layer.
 Further increasing of NG (15 vol%) increased the wear rate
into the upward level as a result of nano particles aggrega-
tion. It is seen that boron carbide reinforcement definitely
improved the higher order magnitude of wear resistance of
the composite.
 However, it could not be realized cooperative effect when both
of reinforcements in 15 vol% during elevated sliding. Because of
the agglomeration effect of nano particles is very dominative as
compared to the reinforcement effect of boron carbide. This
could be the reason for the low wear resistance of the compos-
ite at 15 vol% of nanographite and boron carbide.
 It is understood from this research studies the 10 vol% of nano-
graphite and boron carbide reinforced composite exhibited a
superior wear performance.
Please cite this article as: K. Rajkumar, K. Ramraji, K. M. Nambiraj et al., A study on wear assessment of AA6061-B4C-Nanographite hybrid composite, Mate-
rials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.151
5
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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Please cite this article as: K. Rajkumar, K. Ramraji, K. M. Nambiraj et al., A study on wear assessment of AA6061-B4C-Nanographite hybrid composite, Mate-
rials Today: Proceedings, https://doi.org/10.1016/j.matpr.2019.11.151