Identification and modelling of applicable wear conditions for stir cast Al-composite

Santanu SARDAR; Santanu Kumar KARMAKAR; Debdulal DAS

doi:10.1007/s40544-019-0302-6

Friction 2020, 8(5): 847-873 https://doi.org/10.1007/s40544-019-0302-6

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Open Access | Issue | Published: 02 October 2019

Identification and modelling of applicable wear conditions for stir cast Al-composite

Show Author's Information Hide Author's Information Santanu SARDAR^¹, Santanu Kumar KARMAKAR^¹, Debdulal DAS^²(

)

1 Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Howrah 711103, India

2 Department of Metallurgy and Materials Engineering, Indian Institute of Engineering Science and Technology, Howrah 711103, India

Keywords:

tribology, aluminum matrix composite, design of experiment, Taguchi, multi-response optimization, abrasion mechanism

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SARDAR S, KARMAKAR SK, DAS D. Identification and modelling of applicable wear conditions for stir cast Al-composite. Friction, 2020, 8(5): 847-873. https://doi.org/10.1007/s40544-019-0302-6

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Abstract Full text About this article

Abstract

A comprehensive study of the tribological performance of the Al-Zn-Mg-Cu/Al₂O₃ composite and its matrix alloy is presented in this paper, with a specific emphasis to identify and model the applicable wear conditions where the composite provides a minimum of 50% reduction in wear rate and 25% lowering of the friction coefficient. Two-body abrasion experiments following Taguchi L₂₇ orthogonal design have been performed separately on alloy and composite materials, both prepared by the stir casting method. The influence of crucial control factors including silicon carbide (SiC) abrasive size, load, sliding distance, and velocity on the percentage variations of wear rates and friction coefficients between alloy and composite have been studied using the analysis of variance technique and full quadratic regression method. The dominant control factors are identified as abrasive size, load, and the interaction between abrasive size and load. This has been verified by establishing the influence of abrasive size and load on variations of wear mechanisms like microcutting, microploughing, and delamination, identified by means of in-depth characterization of worn surfaces and generated debris for both alloy and composite. The selection of applicable tribological condition for the composite has been accomplished by adopting the multi-response optimization technique based on combined desirability approach to obtain concurrent optimization of the percentage variations of wear rates and friction coefficients. Predictive models correlating the superiority of tribological performance of composite with abrasion conditions have been developed, and these are found to be accurate (errors <10%), as determined by confirmatory experiment.

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Identification and modelling of applicable wear conditions for stir cast Al-composite

Show Author's information Hide Author's Information Santanu SARDAR^¹, Santanu Kumar KARMAKAR^¹, Debdulal DAS^²(

)

1 Department of Mechanical Engineering, Indian Institute of Engineering Science and Technology, Howrah 711103, India

2 Department of Metallurgy and Materials Engineering, Indian Institute of Engineering Science and Technology, Howrah 711103, India

Abstract

Keywords: tribology, aluminum matrix composite, design of experiment, Taguchi, multi-response optimization, abrasion mechanism

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Publication history

Received: 07 July 2018

Revised: 08 February 2019

Accepted: 11 May 2019

Published: 02 October 2019

Issue date: October 2020

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Acknowledgements

The authors recognize the support obtained from the Centre of Excellence on Microstructurally Designed Advanced Materials Development under TEQIP-II, IIEST Shibpur. The assistance granted from DST-FIST to set up Advanced Tribology Laboratory under the Department of Mechanical Engineering, IIEST Shibpur is also highly appreciated.

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