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Composites: Part B: A. Baradeswaran, A. Elaya Perumal
Composites: Part B: A. Baradeswaran, A. Elaya Perumal
Composites: Part B
journal homepage: www.elsevier.com/locate/compositesb
a r t i c l e i n f o a b s t r a c t
Article history: This work investigated the influence of graphite on the wear behavior of Al 7075/Al2O3/5 wt.% graphite
Received 31 December 2012 hybrid composite. The investigation reveals the effectiveness of incorporation of graphite in the compos-
Received in revised form 22 February 2013 ite for gaining wear reduction. The Al 7075 (aluminium alloy 7075) reinforced with Al2O3–graphite were
Accepted 12 August 2013
investigated. The composites were fabricated using liquid metallurgy route. Ceramic particles along with
Available online 20 August 2013
solid lubricating materials were incorporated into aluminium alloy matrix to accomplish reduction in
both wear resistance and coefficient of friction. The Al 7075/Al2O3/graphite hybrid composite was pre-
Keywords:
pared with 5 wt.% graphite particles addition and 2, 4, 6 and 8 wt.% of Al2O3. The hardness, tensile
A. Metal-matrix composites (MMCs)
A. Particle-reinforcement
strength, flexural strength and compression strength of the Al 7075–Al2O3–graphite hybrid composites
B. Wear are found to be increased by increased weight percentage of ceramic phase. The wear properties of the
E. Casting hybrid composites containing graphite exhibited the superior wear-resistance properties.
Ó 2013 Elsevier Ltd. All rights reserved.
1. Introduction applications [20,21]. Kok and Ozdin [22] investigated the effect of
Al2O3 particle content and size on the wear behavior of Al2O3 par-
Wear is one of the important phenomena that takes place at a ticle reinforced 2024 aluminium alloy composites fabricated by
materials interface metal matrix composites (MMCs) with rein- vortex method. Surappa et al. [23] have studied the influence of
forcement of hard particles that offer superior performance and 5 vol.% Al2O3 particles addition on the wear resistance of hyper
wear resistance [1]. Aluminium based MMCs have been a very eutectic Al–Si alloys. Earlier Straffelini et al. [24] have reported
valuable addition to the field of newer materials for high perfor- on the influence of the matrix hardness on dry sliding wear behav-
mance tribological applications. Aluminium based composites are ior of Al 6061/Al2O3 composites, Yu et al. [25] have studied the ef-
being increasingly used in automobile, aerospace, marine and min- fects of applied load and temperature on the dry sliding behavior of
eral processing industries owing to their improved specific Al 6061/SiC composites, Liang et al. [26] have identified that the
strength, good wear resistance, higher thermal conductivity and MMCs containing SiC particles exhibit improved wear resistance.
lower coefficient of thermal expansion. The widely used reinforced Reda et al. [27] and Clark et al. [28] have reported that pre-aging
materials for this composite are silicon carbide (SiC), aluminium at various retrogation temperatures improves the hardness, tensile
oxide (Al2O3) and graphite in the form of particles or whiskers properties and electrical resistivity of Al 7075. Kim et al. [29] con-
[2–6]. Aluminium matrix composites normally fabricated by liquid cluded that the hardness of aged Al 7075 alloy was increased. Doel
casting technique or powder metallurgy route [7–10]. In the liquid and Bowen [30] have reported the improved tensile strength and
casting technique, the particulates are mechanically well distrib- lower ductility of Al 7075 reinforced with SiC particles than that
uted over the liquid metal before casting and solidification [11– of unreinforced, Komai et al. [31] have identified superior mechan-
14]. These methods are typically cost effective [15,10]. Aluminum ical properties of Al 7075–SiCW composites.
based MMCs reinforced with ceramic particles developed better Generally lubricant is externally added to reduce the wear. This
mechanical properties than unreinforced aluminium alloys poses the problem when the materials need the periodic applica-
[16,17] and are most widely used for tribological parts due to their tions of lubricant particularly to wear parts which are difficult to
high ratio of strength, stroke density and improved wear resistance access. For such applications self-lubricating materials are pre-
[18,19]. This has been an incentive for increasing attention towards ferred because the solid lubricant contained in them can be auto-
particulate reinforced aluminium alloy composites for tribological matically released during the wear process to reduce the wear.
Graphite is one of the most widely used solid lubricant materials.
⇑ Corresponding author. Address: Department of Mechanical Engineering, Madha Earlier researchers [32–35] have already focused their investiga-
Engineering College,Chennai 600 069, India. Tel.: +91 9710363105; fax: +91 44 tion on applications of aluminium graphite composite. There are
24780798. also earlier reports from some investigators [36,37] who identified
E-mail address: barathme@yahoo.co.in (A. Baradeswaran).
1359-8368/$ - see front matter Ó 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compositesb.2013.08.013
A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471 465
the trend that aluminium graphite composite containing the small An OHNS (Oil Hardened Nickel Steel) 55 mm diameter steel disc
amount of graphite exhibit superior wear properties over the base of 60HRc was used as the counter surface in the wear test. The test
alloys. The limitation with the aluminium graphite composite is in was conducted with various loads of 20 N, 40 N and 60 N at a slid-
using graphite as a solid lubricant whose introduction results in ing speed of 0.6, 0.8 and 1.0 m/s for the constant sliding distance of
the loss of strength of the composite. 2000 m. The test was conducted at room temperature (30 °C) and
It is, therefore, proposed to undertake a study on the effective- relative humidity of 60–65%.
ness of reinforcements mixed with Al 7075. Aluminum with 5 wt.% The initial weight of the specimen was measured in an elec-
of graphite is reinforced with Al2O3 to form a stronger hybrid com- tronic weighing machine with a least count of 0.0001 g. A strain
posite (Al 7075/Al2O3/graphite). gauged friction detecting arm holds and loads the pin specimen
vertically on a rotating hardened steel disc. The frictional traction
encounted by the pin during sliding is measured continuously by
2. Materials and methods
a PC-based data-logging system for analysis. The wear test was
conducted after the initial run in period when the pin specimens
2.1. Chemicals and instruments
were entirely in contact with the disc surface. In each test after
running the fixed sliding distance the specimen was removed,
Al 7075, graphite and Al2O3 were purchased from Krishmet
cleaned with acetone, dried and weighed to determine the weight
India Pvt. Ltd., Chennai. The casting facility was used from Madras
loss due to wear. The wear rates were determined using the weight
Institute of Technology (MIT), Chrompet, Chennai. The wear and
loss method.
friction tests were measured using pin on disc apparatus (model:
02), IIT Madras, Chennai, India. The flexural strength was measured
2.4. Hardness test
using UTM machine (UTE40). The scanning electron micrographs
(SEMs) were recorded using Hitachi-S3400 scanning electron
The hardness tests were carried out according to ASTM E10-07
microscope (SEM).
standards using Brinell hardness testing machine with a 10 mm
ball indenter and 500 kg load for 30 s. The test was conducted at
2.2. Material fabrication room temperature (30 °C) and the measurement of hardness was
taken at five different places on each sample to obtain an average
The chemical compositions of the Al 7075 alloy is given in Table 1. value of hardness.
The Al 7075 containing 5 wt.% graphite composite was reinforced
with 2, 4, 6 and 8 wt.% Al2O3 about an average particulate size of 2.5. Tensile test
16 lm were prepared by a stir casting process. About 1.0 kg of Al
7075 alloy is melted in a graphite crucible heated to 850 °C. When As per the ASTM E08-8 standard, the tensile strength was eval-
the temperature of the melt is about 30 °C above the pouring tem- uated on the cylindrical rod of casted composites. The 1200 grit
perature preheated stirrer is introduced in the melt. Agitation of grinding SiC paper was used to polish the test specimens in order
the melt is started and the preheated Al2O3 particulates are intro- to decrease the machining scratches and the effects of surface de-
duced in the wt.% of 2, 4, 6 and 8 and followed by the addition of fects on the sample. The universal testing machine (UTM-Auto
5 wt.% graphite. The mixture was stirred at 500 rpm for 5 min by instrument) loaded with 10 kN load cell was used to conduct the
means of a spiral-shaped stirrer coupled to a motor and the temper- tensile test. The tensile strength was evaluated at cross head speed
ature was kept persistent at 850 °C. Due to the stirring action, the of 2.5 mm/min.
melted aluminium alloy was split into droplets owing to the shear
forces brought by the impeller due to the existence of graphite. 2.6. Compression test
The stirring is continued to ensure a proper mixing and slurry. The
slurry of the composites thus prepared was poured into the pre- The compression test was performed on these samples with
heated steel moulds. The composite were given a T6 heat treatment computerized universal Testing Machine (UTM-Auto instrument))
and the specimens for hardness, tensile strength, compressive at room temperature and ultimate compression strength of these
strength, flexural strength and wear test were prepared from these samples was measured as per ASTM E9-09 standards. Since it is a
composites. computerized machine the ultimate compressive strength was re-
corded accurately. The test was conducted at a cross head speed of
1 mm/min.
2.3. Wear test
2.7. Three point bending test
A pin on disc test apparatus shown in Fig. 1 was used to inves-
tigate the dry sliding wear behavior of Al 7075/Al2O3/5 wt.% graph-
Three point bending test was realistic instead of tensile test
ite hybrid composites. Pin specimens of 6 mm diameter and
and compression test in investigating of particle reinforced metal
15 mm height for wear test was prepared from the above compos-
matrix composites. The main reason was aluminium oxide
ites were machined and polished metallographically.
particulates make the notch effect during testing. Since
machining of Al2O3 reinforced aluminium matrix composites,
Table 1 surface is a very subtle and special process, structure may be
Chemical composition of Al 7075. weakened. Machining was done with high speed diamond
Element Symbol Composition % in Al 7075
tools.
Three point bending test was performed to reveal the flexural
Zinc Zn 5.4
Copper Cu 1.42
strength of aluminum with 5 wt.% of graphite composite and
Manganese Mn 0.12 with different percentage additions of aluminium oxide. In
Magnesium Mg 2.42 three-point bending test, the maximum bending load was evalu-
Ferrite Fe 0.42 ated. This load value was converted into flexural strength (MPa)
Chromium Cr 0.21
value. The three point bending test specimens were shown in
Aluminium Al Remaining
Fig. 2.
466 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471
The effect of graphite and Al2O3 on the hardness and the tensile
strength of the composite obtained from hardness test and tensile
test are shown in Figs. 3 and 4. The hardness measurements were
carried out on a Brinell hardness testing machine.
From Fig. 3 it is observed that the hardness of the Al 7075/
Al2O3/graphite hybrid composite increases with the addition of
Al2O3. It was higher than that of base alloy. Hardness of all the hy- Fig. 4. Variation of tensile strength with varying content of Al2O3 and 5 wt.%
brid composites was significantly greater than that of the base al- graphite.
A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471 467
Fig. 5. Variation in compression strength with varying Al2O3. Fig. 7. Wear rate of Al 7075/Al2O3/5 wt.% graphite hybrid composites.
468 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471
Fig. 8. Wear rate of hybrid composites with varying sliding speeds. Fig. 9c. Scanning electron micrograph of worn surface of Al 7075/4 wt.% Al2O3/
5 wt.% graphite.
Fig. 9d. Scanning electron micrograph of worn surface of Al 7075/6 wt.% Al2O3/
5 wt.% graphite.
Fig. 9b. Scanning electron micrograph of worn surface of Al 7075/2 wt.% Al2O3/
5 wt.% graphite.
ing film on the tribo surface of the hybrid composites. The de-
creased wear rate of hybrid composite with graphite content can
be ascribed to the collective effects of graphite and Al2O3 particles Fig. 9e. Scanning electron micrograph of worn surface of Al 7075/8 wt.% Al2O3/
in formation of a more resistant tribolayer on the contact surface 5 wt.% graphite.
[10,49,56,62]. The graphite tribo film minimize the degree of shear
stress transferred to the sliding material underneath the sliding
contact area which results in less plastic deformation in the sub Oxidation of metallic particle occurs in the working atmosphere
surface region and reduces the wear rate in the hybrid composites. and oxides are formed which spread and form a layer on the pin
A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471 469
surface. Once the oxide layers are formed; distortion, spalling and
fracture of the layers take place over the pin mating surface in the
course of sliding. All the oxides are not completely dislodged from
the mating surface, some amounts present between the mating
surfaces offers wear resistance due to the dilution of metallic con-
tact of the surface. But as the load exceeded a certain value a sig-
nificant decrease in wear resistance is observed, so at higher
loads gross damage occurs to the pin material [68].
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