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Lubricants
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Wear Behavior of Aluminum Matrix Composite
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Wear Behavior of Aluminum Matrix Composite

A special issue of Lubricants (ISSN 2075-4442).

Deadline for manuscript submissions: closed (31 December 2023) | Viewed by 10116

Special Issue Editors

Dr. Carlos G. Garay Reyes

E-Mail Website
Guest Editor
Department of Metallurgy and Structural Integrity, Center for Research in Advanced Materials, Chihuahua 31136, Mexico
Interests: high-entropy alloys; metal matrix composite; aluminum alloys; Ni-based alloys; phase transformations; mechanical properties
Special Issues, Collections and Topics in MDPI journals
Dr. Ivanovich Estrada-Guel

E-Mail Website
Guest Editor
Centro de Investigación en Materiales Avanzados (CIMAV), Miguel de Cervantes No. 120, Chihuahua 31109, Mexico
Interests: mechanical alloying; materials characterization; composites; material reinforcement; sintering
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Aluminum-based composites are a class of metal matrix composites that can be successfully used in the aerospace, structural, and automotive industries. However, their applications have often been restricted due to their moderate wear resistance. The development of improved wear-resistant aluminum-based matrix composites is receiving considerable attention from the scientific and technological community. Although notable research has been carried out on processing and mechanical properties, further studies are constantly required. Thus, the design, synthesis, and development of new aluminum-based compounds with better wear properties is the challenge of the new generation of researchers.

Dr. Carlos G. Garay Reyes
Dr. Ivanovich Estrada-Guel
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Lubricants is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • wear behavior
  • microstructure
  • aluminum matrix composite materials
  • wear surface analysis
  • worn surface and wear debris

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Published Papers (5 papers)

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Research

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19 pages, 6088 KiB  
Article
Tribological Behaviour of Hypereutectic Al-Si Composites: A Multi-Response Optimisation Approach with ANN and Taguchi Grey Method
by Slavica Miladinović, Sandra Gajević, Slobodan Savić, Ivan Miletić, Blaža Stojanović and Aleksandar Vencl
Lubricants 2024, 12(2), 61; https://doi.org/10.3390/lubricants12020061 - 17 Feb 2024
Cited by 6 | Viewed by 1761
Abstract
An optimisation model for small datasets was applied to thixocasted/compocasted composites and hybrid composites with hypereutectic Al-18Si base alloys. Composites were produced with the addition of Al2O3 (36 µm/25 nm) or SiC (40 µm) particles. Based on the design of [...] Read more.
An optimisation model for small datasets was applied to thixocasted/compocasted composites and hybrid composites with hypereutectic Al-18Si base alloys. Composites were produced with the addition of Al2O3 (36 µm/25 nm) or SiC (40 µm) particles. Based on the design of experiment, tribological tests were performed on the tribometer with block-on-disc contact geometry for normal loads of 100 and 200 N, a sliding speed of 0.5 m/s, and a sliding distance of 1000 m. For the prediction of the tribological behaviour of composites, artificial neural networks (ANNs) were used. Three inputs were considered for ANN training: type of reinforcement (base alloy, Al2O3 and SiC), amount of Al2O3 nano-reinforcement (0 and 0.5 wt.%), and load (100 and 200 N). Various ANNs were applied, and the best ANN for wear rate (WR), with an overall regression coefficient of 0.99484, was a network with architecture 3-15-1 and a logsig (logarithmic sigmoid) transfer function. For coefficient of friction (CoF), the best ANN was the one with architecture 3-6-1 and a tansig (hyperbolic tangent sigmoid) transfer function and had an overall regression coefficient of 0.93096. To investigate the potential of ANN for the prediction of two outputs simultaneously, an ANN was trained, and the best results were from network 3-5-2 with a logsig transfer function and overall regression coefficient of 0.99776, but the predicted values for CoF in this case did not show good correlation with experimental results. After the selection of the best ANNs, the Taguchi grey multi-response optimisation of WR and CoF was performed for the same combination of factors as the ANNs. For optimal WR and CoF, the combination of factors was as follows: composite with 3 wt.% Al2O3 micro-reinforcement, 0.5 wt.% Al2O3 nano-reinforcement, and a load of 100 N. The results show that developed ANN, the Taguchi method, and the Taguchi grey method can, with high reliability, be used for the optimisation of wear rate and coefficient of friction of hypereutectic Al-Si composites. Microstructural investigations of worn surfaces were performed, and the wear mechanism for all tested materials was light abrasion and adhesion. The findings from this research can contribute to the future development of hypereutectic Al-Si composites. Full article
(This article belongs to the Special Issue Wear Behavior of Aluminum Matrix Composite)
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Figure 1

Figure 1
<p>Microstructures of produced composites: (<b>a</b>) matrix material Al-18Si and (<b>b</b>) composite with 0.5 wt.% Al<sub>2</sub>O<sub>3</sub> (25 nm) and 3 wt.% Al<sub>2</sub>O<sub>3</sub> (36 µm).</p> Full article ">Figure 2
<p>Schematics of contact pair.</p> Full article ">Figure 3
<p>Schematic model of simplified ANN.</p> Full article ">Figure 4
<p>Regression coefficients for the best ANN for (<b>a</b>) wear rate (WR), (<b>b</b>) coefficient of friction (CoF), and (<b>c</b>) both outputs.</p> Full article ">Figure 5
<p>Diagrams of S/N ratio: (<b>a</b>) main effect for wear rate, (<b>b</b>) interaction plot for wear rate, (<b>c</b>) main effect for CoF, and (<b>d</b>) interaction plot for CoF.</p> Full article ">Figure 6
<p>Comparative display of the experimental results and ANN predictions for (<b>a</b>) wear rate and (<b>b</b>) coefficient of friction.</p> Full article ">Figure 7
<p>SEM micrograph of worn surfaces: (<b>a</b>) matrix alloy and (<b>b</b>) Al-18Si with 0.5 wt.% Al<sub>2</sub>O<sub>3</sub> nanoparticles and 3 wt.% Al<sub>2</sub>O<sub>3</sub> microparticles.</p> Full article ">Figure 8
<p>EDS analysis of Al-18Si with 0.5 wt.% Al<sub>2</sub>O<sub>3</sub> nanoparticles and 3 wt.% Al<sub>2</sub>O<sub>3</sub> microparticles tested under 100 N normal load: (<b>a</b>) spectrum positions, (<b>b</b>) Spectrum 1, and (<b>c</b>) Spectrum 2.</p> Full article ">
16 pages, 6062 KiB  
Article
Friction and Wear in Stages of Galling for Sheet Metal Forming Applications
by Timothy M. Devenport, James M. Griffin, Bernard F. Rolfe and Michael P. Pereira
Lubricants 2023, 11(7), 288; https://doi.org/10.3390/lubricants11070288 - 7 Jul 2023
Cited by 4 | Viewed by 1736
Abstract
Aluminum is a very commonly used material at present, and roughly half of the produced aluminum products undergo forming during manufacturing. Galling is a severe form of wear that occurs during sheet metal forming operations and is a common failure mode of materials [...] Read more.
Aluminum is a very commonly used material at present, and roughly half of the produced aluminum products undergo forming during manufacturing. Galling is a severe form of wear that occurs during sheet metal forming operations and is a common failure mode of materials in sliding contact; however, the causes and mechanisms of galling are poorly understood. In this work, sliding wear experiments were conducted to produce galling wear between a tool steel ball bearing and aluminum alloy Al5083, to study the relationship between the coefficient of friction, the lump growth on the tool and the scratch morphology. Whilst the characteristic friction regimes were observed, the characteristic damage (grooves running parallel to the scratch direction) was not observed. Instead, when galling was developed on the indenter, the scratch surface morphology displayed a series of peaks and grooves perpendicular to the scratch direction. It is likely that the difference in scratch morphology observed once galling was initiated is due to the lower hardness and reduced work hardening behavior of the Al5083 alloy, compared to the high strength steels previously examined in sheet metal forming applications. The evolution of the scratch morphology has been characterized in a novel way by investigating the distribution of the longitudinal cross-section profile height along the scratch length in relation to the three-stage friction regime observed. This showed that, as the galling wear progressed, the longitudinal cross-section profile height distribution shifts towards negative values, with a corresponding shift in the distribution of material transferred to the tool shifting to the positive. This indicates that, as the amount of material adhered to the indenter increased, the depth of the grooves on the scratch surface perpendicular to the sliding direction also increased. Full article
(This article belongs to the Special Issue Wear Behavior of Aluminum Matrix Composite)
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Figure 1

Figure 1
<p>Typical friction curve for progressing galling wear, adapted with permission from Eriksson et al. [<a href="#B11-lubricants-11-00288" class="html-bibr">11</a>].</p> Full article ">Figure 2
<p>Sheet morphology from a slider on flat sheet tests of steel-on-steel under a 125 N load, and 630 mm/min sliding speed, reproduced with permission from Sindi et al. [<a href="#B14-lubricants-11-00288" class="html-bibr">14</a>].</p> Full article ">Figure 3
<p>Optical microscopy images of the aluminium alloy wear track, showing how the damage evolves with friction (at elevated temperature of 300 °C), reproduced with permission from Yang et al. [<a href="#B16-lubricants-11-00288" class="html-bibr">16</a>].</p> Full article ">Figure 4
<p>Bruker TriboLab UMT as used for this experimental regime.</p> Full article ">Figure 5
<p>Example of the profile form measurement of a test that exhibited stage 3 galling. The white arrow indicates the indenter sliding direction.</p> Full article ">Figure 6
<p>Example coefficient of friction curve for progressing galling wear.</p> Full article ">Figure 7
<p>Coefficient of friction curves for all tests. Refer to <a href="#lubricants-11-00288-t003" class="html-table">Table 3</a> for reference on the tests and stages.</p> Full article ">Figure 8
<p>Lump growth on the tool. (<b>A</b>) Unworn, (<b>B</b>) 50 mm sliding, (<b>C</b>) 100 mm sliding, (<b>D</b>) 150 mm sliding. The white arrow indicates the sheet sliding direction.</p> Full article ">Figure 9
<p>Lump growth—volume of material transferred to the indenter for each galling stage.</p> Full article ">Figure 10
<p>Cross-sections of lump growth on all of the indenters after each segment of the scratch tests, separated by the stage of galling. The sheet sliding direction is from left to right.</p> Full article ">Figure 11
<p>Distribution of the build-up on the indenter.</p> Full article ">Figure 12
<p>Magnified images of the three stages of galling wear for the different galling stages: (<b>A</b>) stage 1, (<b>B</b>) stage 2, (<b>C</b>) stage 3.</p> Full article ">Figure 13
<p>Evolution of the scratch morphology along the scratch length, within the scratch width.</p> Full article ">Figure 14
<p>Distribution of series of peaks and troughs in the scratch after each stage of galling.</p> Full article ">
16 pages, 20530 KiB  
Article
Effect of Rotational Speed on Tribological Properties of Carbon Fiber-Reinforced Al-Si Alloy Matrix Composites
by Feng Tang, Xiaotao Pan, Yafei Deng, Zhenquan Zhou, Guoxun Zeng and Sinong Xiao
Lubricants 2023, 11(3), 142; https://doi.org/10.3390/lubricants11030142 - 17 Mar 2023
Cited by 5 | Viewed by 1554
Abstract
Porous carbon fiber-reinforced Al-Si alloy matrix composites and carbon fiber felt-reinforced Al-Si alloy matrix composites with carbon content of 10 wt.% were prepared by die casting. The dry tribological properties of these two composites and Al-Si alloy were studied using a ball-on-disc rotational [...] Read more.
Porous carbon fiber-reinforced Al-Si alloy matrix composites and carbon fiber felt-reinforced Al-Si alloy matrix composites with carbon content of 10 wt.% were prepared by die casting. The dry tribological properties of these two composites and Al-Si alloy were studied using a ball-on-disc rotational tribometer in the rotational speed range of 300 r/min to 1000 r/min, and the wear mechanisms were analyzed in combination with the wear morphology. The results show that the friction coefficient and wear rate of these two composites are lower than the Al-Si alloy at different speeds. With the increase in rotational speed, the friction coefficient of the two composites and Al-Si alloy first increases and then decreases, and the wear rate gradually increases. The wear mechanisms of the two composites and Al-Si alloy change from abrasive wear and adhesive wear to delamination wear, but the node speed of the change in the wear mechanism of the composites to delamination wear is higher, and the wear degree is relatively slight. In addition, the comprehensive tribological properties of carbon fiber felt-reinforced Al-Si alloy matrix composites are better than the porous carbon fiber-reinforced Al-Si alloy matrix composites. Full article
(This article belongs to the Special Issue Wear Behavior of Aluminum Matrix Composite)
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Figure 1

Figure 1
<p>Microstructures of two CFs: (<b>a</b>) CF<sub>p</sub>; (<b>b</b>) CF<sub>f</sub>.</p> Full article ">Figure 2
<p>Schematic diagram of ball-on-disc rotational tribometer.</p> Full article ">Figure 3
<p>XRD patterns of Al-Si alloy and Al-Si/CF<sub>p</sub>, Al-Si/CF<sub>f</sub> composites.</p> Full article ">Figure 4
<p>SEM images and EDS maps of samples: (<b>a</b>) Al-Si/CF<sub>f</sub> composite; (<b>b</b>) Al-Si/CF<sub>p</sub> composites; (<b>c</b>) Al-Si alloy.</p> Full article ">Figure 5
<p>COF curves of Al-Si alloy and Al-Si/CF<sub>f</sub>, Al-Si/CF<sub>p</sub> composites at various rotational speeds: (<b>a</b>) 300 r/min; (<b>b</b>) 500 r/min; (<b>c</b>) 800 r/min; (<b>d</b>) 1000 r/min.</p> Full article ">Figure 6
<p>Average COF of Al-Si alloy and Al-Si/CF<sub>p</sub>, Al-Si/CF<sub>f</sub> composites at various rotational speeds.</p> Full article ">Figure 7
<p>Wear rate of Al-Si alloy and Al-Si/CF<sub>p</sub>, Al-Si/CF<sub>f</sub> composites at various rotational speeds.</p> Full article ">Figure 8
<p>SEM images of the worn surface morphologies of Al-Si alloy at various rotational speeds: (<b>a</b>) 300 r/min; (<b>b</b>) 500 r/min; (<b>c</b>) 800 r/min; (<b>d</b>) 1000 r/min.</p> Full article ">Figure 9
<p>SEM images and EDS maps of worn surface of the counterpart ball against the Al-Si alloy at 500 r/min.</p> Full article ">Figure 10
<p>SEM images of the worn surface morphologies of Al-Si/CF<sub>p</sub> composites at various rotational speeds: (<b>a</b>) 300 r/min; (<b>b</b>) 500 r/min; (<b>c</b>) 800 r/min; (<b>d</b>) 1000 r/min.</p> Full article ">Figure 11
<p>SEM images and EDS maps of worn surface of the counterpart ball against the Al-Si/CF<sub>p</sub> composite at 500 r/min.</p> Full article ">Figure 12
<p>SEM images of the worn surface morphologies of Al-Si/CF<sub>f</sub> composites at various rotational speeds: (<b>a</b>) 300 r/min; (<b>b</b>) 500 r/min; (<b>c</b>) 800 r/min; (<b>d</b>) 1000 r/min.</p> Full article ">Figure 13
<p>SEM images and EDS maps of the worn surface of the counterpart ball against the Al-Si/CF<sub>f</sub> composite at 500 r/min.</p> Full article ">Figure 14
<p>Physical models of wear mechanism of Al-Si/CF composites at various rotational speeds: (<b>a</b>) 300 r/min; (<b>b</b>) 500 r/min; (<b>c</b>) 800 r/min; (<b>d</b>) 1000 r/min.</p> Full article ">
12 pages, 3763 KiB  
Article
Abrasive Wear Behavior of Al–4Cu–1.5Mg–WC Composites Synthesized through Powder Metallurgy
by Gustavo Rodríguez-Cabriales, Carlos G. Garay-Reyes, Juan C. Guía-Tello, Hansel M. Medrano-Prieto, Ivanovich Estrada-Guel, Lilia J. García-Hernández, Marco A. Ruiz-Esparza-Rodríguez, José M. Mendoza-Duarte, Karen A. García-Aguirre, Sergio Gonzáles-Sánchez and Roberto Martínez-Sánchez
Lubricants 2023, 11(3), 103; https://doi.org/10.3390/lubricants11030103 - 27 Feb 2023
Cited by 2 | Viewed by 1789
Abstract
Different Al–4Cu–1.5Mg/WC composites were synthesized through powder metallurgy to establish the effect of WC particle addition on the abrasive wear behavior of an Al–4Cu–1.5Mg (wt. %) alloy. The wear tests were performed using a pin-on-disc tribometer at room temperature in dry conditions using [...] Read more.
Different Al–4Cu–1.5Mg/WC composites were synthesized through powder metallurgy to establish the effect of WC particle addition on the abrasive wear behavior of an Al–4Cu–1.5Mg (wt. %) alloy. The wear tests were performed using a pin-on-disc tribometer at room temperature in dry conditions using SiC abrasive sandpaper as a counterbody and tribometer of linear configuration. The results showed that WC additions increase the hardness of the Al–4Cu–1.5Mg alloy due to the strengthening effect of particle dispersion in the aluminum matrix, which generates an improvement in the wear resistance of the composites by preventing direct contact of the sample with the counterbody, in turn delaying the plastic deformation phenomena responsible for the degradation sequence. In addition, the dominant wear mechanism was abrasive wear, and the increased friction coefficient did not bring a rapid wear rate, which was related to the enhanced deformation resistance due to the high hardness. Full article
(This article belongs to the Special Issue Wear Behavior of Aluminum Matrix Composite)
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Graphical abstract

Graphical abstract
Full article ">Figure 1
<p>The principle of linear configuration test (<b>a</b>) and pin-on-disc tests (<b>b</b>).</p> Full article ">Figure 2
<p>SEM backscattered electron images corresponding to the initial powders and green and annealing conditions for Al–4Cu–1.5Mg alloy with 1 wt. % WC.</p> Full article ">Figure 3
<p>XRD patterns of (<b>a</b>) Al–4.5Cu–1.5Mg + 3WC after extrusion and annealing, and (<b>b</b>) the Al–4Cu–1.5Mg alloy with 0, 1, 2, and 3 wt. % tungsten carbide (WC) particles after annealing.</p> Full article ">Figure 4
<p>Evolution of the Vickers hardness with WC concentration up to 3 wt. %.</p> Full article ">Figure 5
<p>Wear rate of the Al-4Cu-1.5Mg alloy and the composites with 0, 1, 2, and 3 wt. % tungsten carbide (WC) particles for the different sandpaper numbers during the pin-on-disc test at 3 and 5 N.</p> Full article ">Figure 6
<p>Coefficient of friction (COF) of Al–4Cu–1.5Mg and Al–4Cu–1.5Mg + 3WC composite subjected to 5 N of load (<b>a</b>) and the average coefficient of friction (COF) of the composites with 1, 2, and 3 WC (wt. %) after the test at loads of 3 and 5 N (<b>b</b>).</p> Full article ">Figure 7
<p>SEM secondary electron images from the worn surfaces in the Al–4.5Cu–1.5Mg alloy and the Al–4Cu –1.5Mg + 3WC composite. The samples correspond to the pin-on-disc test using 180 grit sizes of SiC abrasive sandpaper under 5 N of load and a sliding distance of 300 m.</p> Full article ">Figure 8
<p>SEM backscattered electron images and EDX elemental mapping of the worn surface in the Al–4.5Cu–1.5Mg alloy (<b>a</b>) and the Al–4Cu–1.5Mg + 3WC composite (<b>b</b>). The mappings correspond to Al, Cu, Mg, and W elements, and the circle highlights delamination features.</p> Full article ">

Review

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20 pages, 2565 KiB  
Review
A Review of the Friction and Wear Behavior of Particle-Reinforced Aluminum Matrix Composites
by Yunlei Wang and Jie Zhang
Lubricants 2023, 11(8), 317; https://doi.org/10.3390/lubricants11080317 - 27 Jul 2023
Cited by 6 | Viewed by 2462
Abstract
Aluminum matrix composites are key materials used in the preparation of lightweight structural parts. It has the advantages of low density, high specific strength, and high specific stiffness. Additionally, its friction and wear properties are important factors that determine the material’s suitability for [...] Read more.
Aluminum matrix composites are key materials used in the preparation of lightweight structural parts. It has the advantages of low density, high specific strength, and high specific stiffness. Additionally, its friction and wear properties are important factors that determine the material’s suitability for use in a batch. Therefore, this paper systematically analyzes the current research on the friction and wear behavior of particle-reinforced aluminum matrix composites. It also discusses the effects of various internal factors, such as the microstructure characteristics of the matrix materials and the state of the reinforced particles, as well as external factors like wear pattern, applied load, sliding speed, thermal treatment, and temperature on the friction and wear properties of these composites. The applications of particle-reinforced aluminum matrix composites in the fields of transportation, aerospace, and electronics are summarized. In addition, this paper discusses the current research status and future development trends regarding the wear behavior of particle-reinforced aluminum matrix composites. Finally, this study aims to provide technical references for researching the friction and wear properties of particle-reinforced aluminum matrix composites. It is intended to benefit scientific researchers and engineering technicians and provide insights for the development of new composite materials in the future. Full article
(This article belongs to the Special Issue Wear Behavior of Aluminum Matrix Composite)
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Figure 1

Figure 1
<p>Framework of this review.</p> Full article ">Figure 2
<p>Preparation process of (<b>a</b>) the schematic of stir casting process for particle-reinforced aluminum matrix composites, (<b>b</b>) preparation for experimental sample, (<b>b1</b>–<b>b6</b>) six kinds of experimental samples were prepared, respectively. Reproduced with permission from Ref. [<a href="#B30-lubricants-11-00317" class="html-bibr">30</a>]. Copyright 2022 The Author(s).</p> Full article ">Figure 3
<p>Friction coefficient of (<b>a</b>) Al-SiC, (<b>b</b>) Al-CNT composite. Reproduced with permission from Ref. [<a href="#B33-lubricants-11-00317" class="html-bibr">33</a>]. Copyright 2019 The Authors.</p> Full article ">Figure 4
<p>(<b>a</b>) schematic diagram for ultrasonically assisted stir casting, (<b>b</b>) mechanical properties of the as-cast Al-SiC nanocomposites, (<b>c</b>) stress–strain curves for the as-cast Al-SiC nanocomposites, (<b>d</b>) yield strength due to experimentally predicted and strengthening mechanisms. Reproduced with permission from Ref. [<a href="#B38-lubricants-11-00317" class="html-bibr">38</a>]. Copyright 2023 The Author(s).</p> Full article ">Figure 5
<p>Friction coefficient, wear rate, and wear depth of TiH<sub>2</sub>@ZrH<sub>2</sub> reinforced aluminum matrix composites. Reproduced with permission from Ref. [<a href="#B49-lubricants-11-00317" class="html-bibr">49</a>]. Copyright 2023 The Author(s).</p> Full article ">Figure 6
<p>Wear rate analysis of (<b>a</b>) 3T10, (<b>b</b>) 3G10, (<b>c</b>) 3TG10. Reproduced with permission from Ref. [<a href="#B59-lubricants-11-00317" class="html-bibr">59</a>]. Copyright 2023 Elsevier Ltd.</p> Full article ">Figure 7
<p>Effect of applied load on wear behavior (<b>a</b>) average run in wear rate, (<b>b</b>) average steady state wear rate. Reproduced with permission from Ref. [<a href="#B59-lubricants-11-00317" class="html-bibr">59</a>]. Copyright 2023 Elsevier Ltd.</p> Full article ">Figure 8
<p>Diagram of the microstructure evolution of aluminum matrix composite samples under sliding wear at different temperatures. Reproduced with permission from Ref. [<a href="#B79-lubricants-11-00317" class="html-bibr">79</a>]. Copyright 2023 Elsevier Ltd and Techna Group S.r.l.</p> Full article ">Figure 9
<p>Schematic diagram of pin–disk friction and wear and the grinding surface morphology.</p> Full article ">
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