European Journal of Scientific Research ISSN 1450-216X Vol. 93 No 3 December, 2012, pp.321-330 EuroJournals Publishing, Inc. 2012 http://www.europeanjournalofscientificresearch.

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Wear Behaviour of 2024 Al Alloy SiC Gr Hybrid Metal Matrix Composites Prepared by Stir Casting
K. P. Dhanabalakrishnan Associate Professor, Department of Mechanical Engineering Sri Eshwar College of Engineering, Coimbatore, India E-mail: kpdhanabal@gmail.com R. Subramanian Associate Professor, Department of Metallurgical Engineering PSG College of Technology, Coimbatore, India A. Charles Principal, Dhanalakshmi Srinivasan College of Engineering and Technology Coimbatore, India B. Anandavel Assistant Professor, Department of Metallurgical Engineering PSG College of Technology, Coimbatore, India J. Abuthakir Assistant Professor, Department of Mechanical Engineering Sri Eshwar College of Engineering, Coimbatore, India Abstract Al 2024 alloy reinforced with 2.5%, 5.0% and 7.5% (weight percentage) SiC particulates and 5% (weight percentage) Graphite particles were fabricated using liquid metallurgy route (stir casting). The fabricated samples were tested for their wear behaviour at different conditions of process parameters such as applied load, sliding distance and percentage composition. The wear behaviour was studied by dry sliding wear test following ASTM G99. Experiments were planned and executed using Taguchis L27 orthogonal array. Analysis such as S/N ratio analysis, ANOVA analysis, Main Effect Plots and Linear Regression model generated through Minitab 16 software were used to evaluate and find optimum conditions of process parameters at which response of the composites in this study was low. The response chosen was wear volume loss and quality characteristics adopted for S/N ratio analysis was smaller is better type. Finally confirmations experiments were conducted to compare and validate the multiple linear regression models, thus verifying the experimental results.

Keywords: Metal Matrix Composites, SiC, Dry Sliding Wear test, Taguchis L27 orthogonal array, process parameters, Multiple Linear regression model.

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1. Introduction
In recent years, increasing demand for light weight, fuel efficient and comfort materials in aerospace and automobile industries has led to the development of advanced materials coupled with optimized design. Composite materials in this regard represent a giant step in the ever increasing efforts for development and optimization in materials field. Among the different classes of composites, Metal Matrix Composites, in particular Aluminium Matrix Composites are finding increasing number of applications in above mentioned sectors. Silicon Carbide reinforced aluminium matrix composites have found widespread use in engineering industries due to their high strength and high specific modulus [1].Compared to monolithic materials, metal matrix composites exhibit lower wear rates due to the presence of hard reinforcements. Factors such as the type, size and shape of reinforcements influence the wear rate of composites. Commonly used reinforcements such as particle, whisker and fibres influence the wear characteristics of composite. Gurcan et al [2] have concluded that increasing the percentage silicon carbide particulates resulted in improved wear resistance. Increasing the SiC particulates increases the hardness of the material thereby reducing the wear. Serdar Osman ilyaz [3] in the study of comparison on wear behaviour of SiCrFe, CrFeC and Al2O3 reinforced Al 2024 MMCs had concluded that increased hardness resulted in the lower wear rate. Mingwu Bai et al [4] had concluded had concluded in the study of tribological properties of SiC whisker and molybdenum reinforced aluminium matrix composites under lubrication that reinforcement particulates increases the wear resistance of the material. Qunji xue et al [5] had concluded in the study of wear of 2024 Al-Mo-SiC composites under lubrication that the addition of SiC whiskers increased the wear resistance of the material. Jiang Xu et al [6] had concluded in the study of wear characteristic of in situ synthetic TiB2 particulate reinforced Al matrix composite formed by laser cladding that with increasing TiB2 content wear resistance of the material improved. The dry sliding wear of aluminium matrix composites reinforced by Be2Al2O3 (SiO3)6 have been reported by Bhaskar et.al [7]. Taguchi L9 Design of Experiment approach for investigation on wear behaviour of Al- Be2Al2O3 (SiO3)6 was chosen and it was concluded that load and sliding distance had the maximum influence on the wear rate. Subbaya et al [8] had conducted study on three body abrasive wear of graphite filled carbon epoxy composites and it was concluded that presence of graphite improved wear resistance.. Yong wen et al [9] had conducted study on wear mechanism of SiC whisker- reinforced 2024 aluminium alloy matrix composites in oscillating sliding wear tests and concluded that Al-SiC exhibited better wear resistance. Manish Narayanan et al [10] had conducted study on dry sliding wear behaviour of Al alloy 2024 Al2O3 particle metal matrix composites and concluded that matrix reinforced with alumina has got better wear resistance than the pure alloy. Ipek [11] had conducted study on adhesive wear behaviour of B4C and SiC reinforced 4147 Al matrix composites (Al/B4C Al/SiC) and concluded that SiC particles had more effective in the wear resistance of the alloy than the B4C. Huei-long lee et al [12] had conducted study on abrasive wear behaviour of powder metallurgy Al alloy 6061 SiC particle composites and concluded that significant improvements in the wear property of aluminium alloy duet to SiC reinforcements can be expected. Deuis et al [13] had conducted a review on dry sliding wear behaviour of aluminium composites and concluded that little information regarding particulate size and volume fractionated to abrasive or dry sliding wear was available. Ramesh et al [14] had conducted study on wear behaviour of hot extruded Al6061 based composites and concluded that increased contents of reinforcements resulted in decreased wear rate. Subramanian et al [15] had conducted study on influence of sliding speed on the dry sliding wear behaviour and the subsurface deformation on hybrid metal matrix composites and concluded that addition of SiC particles to Al 2219 alloy increases the wear resistance of the composites. Graphites and graphite powders have found wide application in industries because of its self-lubricating property.. However, limited informations are available regarding the wear behaviour of Al 2024 alloy prepared through stir casting. In the present investigation effect of process parameters such as applied load, sliding distance and percentage reinforcement of SiC on the wear behaviour of Al 2024 SiC

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K. P. Dhanabalakrishnan, R. Subramanian, A. Charles, B. Anandavel and J. Abuthakir

Gr hybrid composites were studied using dry sliding wear test and design of experiments methodology (Taguchis L27 orthogonal array).

2. Taguchi Method
Design of Experiments has been formulated for optimization and selection of optimal combination of parameters for a given response. Taguchi technique significantly reduces the number of runs that are needed to model the chosen response, compared with full factorial design. Taguchi technique allows us to organize and interpret the effect of process parameters on the response chosen [16,17]. Taguchi technique uses orthogonal array to represent data. Important step in Taguchi design is selection of factors and assigning number of levels to the factors. The levels which are chosen should have equal intervals. The experimental results obtained through conduction of experiments are than analyzed by using S/N ratio analysis, Analysis of means and analysis of variance of the process parameters (factors). Finally influence of each individual factor on the response chosen would be generated. The present investigation employed Taguchis L27 orthogonal array to study the effect of load, sliding distance and percentage contribution on the wear volume loss and a linear regression model was developed to predict the wear volume loss of the hybrid composites.

3. Material Preparation
Al 2024 alloy was chosen as the matrix material in the present study and its composition is given in Table 1. The monolithic alloy was reinforced with 2.5wt%, 5.0wt%, and 7.5wt% and with Content wt% graphite to synthesize the hybrid composite through stir casting (liquid metallurgy route). The size of SiC and Gr particles were 23m and 45m.SiC particles having high hardness aid in reducing wear by increasing the hardness of the composite, while Graphite in nature possesses excellent selflubricating property [17].
Table 1: Chemical composition of the alloy
Cu 4.8 Mg 1.7 Mn 0.6 Al remainder

Chemical composition Wt%

The composite was prepared by liquid metallurgy route, a most commonly used technique. The matrix was superheated above its melting temperature and preheated particulates were added to it. The molten metal was stirred for duration of 10 minutes and speed of stirrer was set at 300 rpm. The melt was then superheated above the liquids temperature and solidified in a preheated cast iron permanent mould to obtain cylindrical specimens (samples). Dry Sliding wear test specimens were prepared from as cast samples and converted to obtain pins of diameter 10mm and length 30mm [17].

4. Wear Investigation
Pin-on-disc apparatus (DUCOM) was used to study the wear behavior of composites using ASTM G99 -04 standards. The specimens were initially cleaned with acetone and weighted to find its initial mass by using digital electronic balance machine. The specimen (pin) was then held against rotating EN-32 steel disc The parameters chosen for the investigation were load L (in Newton), sliding distance L (in meter) and Percentage reinforcement (% composition). The parameters chosen were at three levels as shown in Table 2. The wear tests were carried out by varying the parameters at three levels as shown in Table 2. The volume loss due to the wear was calculated by method of weights [17]. Smaller-the better quality characteristic was chosen for S/N ratio analysis, since the response, wear volume loss is to be minimized. ANOVA and regression analysis of wear test results were also carried out to study the wear behaviour of the composite. Worn out specimens were subjected to Scanning Electron

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Microscopy(SEM) examination using a JEOL 10 make microscope to identify the progress of wear as well as identification of operating wear mechanisms.

5. Plan of Experiments
The experiments were conducted as per the Taguchi L27 orthogonal array generated through MINITAB software (Table 3). The selection of the orthogonal array is based on the condition that the degrees of freedom for the orthogonal array should be greater than or at least equal to the test parameters [16]. The process parameters chosen for the experiment are (i) applied load (ii) sliding distance and the percentage reinforcement.
Table 2: Process parameters (factors) and their levels
Load , L (N) 20 30 40 Sliding distance, D (M) 1800 2400 3000 Percentage reinforcement, %C (wt %) 2.5 5.0 7.5

Levels 1 2 3

The experiments consisted of 27 tests (each row in L27 orthogonal array) and the columns were assigned with parameters. The first column was assigned to load (L), second column was assigned to the sliding distance (D), and third column was assigned to the SiC content (C).

6. Results and Discussions

The wear loss in volume obtained from the experimentation is tabulated as shown in Table 3. The S/N ratio is calculated through the MINITAB software with quality objective being Smaller is better as minimization of wear volume loss is desirable.
Table 3:
Run 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

L27 orthogonal array

Load,(N) 20 20 20 20 20 20 20 20 20 30 30 30 30 30 30 30 30 30 40 40 40 Sliding distance, D (M) 1800 1800 1800 2400 2400 2400 3000 3000 3000 1800 1800 1800 2400 2400 2400 3000 3000 3000 1800 1800 1800 Percentage reinforcement, %C (wt %) 2.5 5.0 7.5 2.5 5.0 7.5 2.5 5.0 7.5 2.5 5.0 7.5 2.5 5.0 7.5 2.5 5.0 7.5 2.5 5.0 7.5 Wear volume loss (mm3) 2.00831 1.10999 0.91563 2.63157 1.47998 1.20994 3.28947 1.81634 1.50425 4.57063 2.65724 2.19097 6.05955 3.46451 2.87769 7.30609 4.06996 3.36820 7.02908 3.73360 3.10660 S/N ratio (db) 6.05662 0.90638 0.7656 -8.4043 3.39337 1.65528 103425 5.18394 -3.5464 13.1995 8.48862 6.81273 15.6488 10.7928 9.18088 17.2737 12.1918 -10.548 -16.938 11.4426 9.84571

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Table 3:
22 23 24 25 26 27

K. P. Dhanabalakrishnan, R. Subramanian, A. Charles, B. Anandavel and J. Abuthakir

L27 orthogonal array - continued
40 40 40 40 40 40 2400 2400 2400 3000 3000 3000 2.5 5.0 7.5 2.5 5.0 7.5 9.34903 5.21358 4.31654 10.90120 6.05449 5.03597 19.4153 14.3427 12.7027 20.7501 15.6416 14.0417

6.1. S/N Ratio and Main Effects Plot Analysis The effect of factors such as load, sliding distance and SiC content on wear volume loss had been evaluated using S/N ratio response analysis. Factor with the highest S/N ratio always yield the optimum quality with minimum variance [17]. The factor with the strongest influence on the response was determined by the difference between the maximum and minimum value of S/N ratios. The S/N ratio response analysis is shown in Table 4. It can be inferred from the table that the load has got more effect on the wear behaviour of the hybrid composites followed by SiC content and sliding distance. The main effect plots for means of S/N ratios and means of wear volume are shown Figure1 and Figure 2. It can be inferred from these figures that as the load increases the wear volume loss increases. This can be attributed to the fact that at higher loads SiC particles tends to get fractured and penetrate the graphite film thereby abrading the matrix surface, thus increasing the wear volume loss. Similar results were drawn by Venkat Prasat et al in Al-fly ash-Gr hybrid composites [17]. It can be observed from the Figures 1 and 2 that as sliding distance increases the wear volume loss increases. Similar trend was observed in the wear study of Al 6061- SiC composites by Mishra et al [18]. It can be noted from Figures 1 and 2 that as the percentage of SiC increases wear volume loss decreases. This can be attributed to the fact that presence of SiC particulates improves the hardness of the composite thereby reducing the wear volume loss of the composite. Similar inference was reported during investigation on wear rate of Al- SiC composites by Gurcan et al [2].
Table 4: Response table for S/N ratios
Level 1 2 3 Delta Rank Load -4.303 -11.571 -15.013 10.711 1 Sliding distance -8.103 -10.615 -12.169 4.066 3 Percentage reinforcement -14.225 -9.154 -7.508 6.718 2

Figure 1: Main effects plot for Mean Wear Volume Loss

Wear Behaviour of 2024 Al Alloy SiC Gr Hybrid Metal Matrix Composites Prepared by Stir Casting
Figure 2: Main effects plot for Mean of S/N ratios

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6.2. Analysis of Variance (ANOVA) ANOVA analysis was used to determine the process parameters that significantly influencing the wear volume loss (response) as well as their relative contribution to the response. Table 4 shows the results of ANOVA for wear volume loss, carried out for a confidence level of 95%, that is for significance level of = 0.05. Percentage of contribution (P %) of each parameter on response and indicating the degree of influence on the result is given in the last column of Table 5. If the P value is less than 0.05, then the parameter or their interactions can be considered to be statistically significant. It can be observed from Table 5, that load is the most significant
Table 5:
source L D %C L*D L*%C D*%C R.E Total

Analysis of means of wear volume

DF 2 2 2 4 4 4 8 26 Seq SS 83.647 14.385 51.827 2.668 10.583 1.672 0.235 165.017 Adj SS 83.6471 14.3849 51.8272 2.6681 10.5833 1.6716 0.2347 Adj MS 41.8236 7.1925 25.9136 0.66702 2.6458 0.4179 0.0293 F 1425.34 245.12 883.13 22.73 90.17 14.24 P 0.000 0.000 0.000 0.000 0.000 0.001 % contribution 50.68992 8.71728 31.40706 1.61680 6.41327 1.01322 0.14240 100

Parameters having the highest statistical influence (50.68992%) on the dry sliding wear volume loss of composites followed by % SiC (31.40706%) with sliding distance having very little effect. Interactions between different parameters also exhibited very less statistical influence on the wear volume loss. From the analysis of results obtained in Table 5, it can be concluded that the load (L), sliding distance (D), percentage reinforcement (%C) and the interactions among them are significant in influencing wear volume loss of composites, since they have obtained P- value less than 0.05. Mahapatra et al [19] had conducted study on wear behaviour of chopped sugarcane reinforced polymer resin matrix .Taguchi L27 array was chosen as experimental design and it was concluded that load had got significant effect on wear behaviour of composite.

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6.3. Linear Regression Model A linear regression model aims to develop a relationship between two or more decision variables and a response variable. To derive a relation between Load (N), Sliding Distance (D), SiC content (wt %) and wear volume loss a multiple linear regression model was developed using Minitab 15 software. Wear volume loss = -2.87 + 0.215L + 0.00148D 0.636%C (1) Since contribution of the interactions on the wear volume loss is very less compared to individual factors, they were not considered for developing the regression model. The sign associated with the coefficient terms of the factors determines the trend of response with respect to the factor. If the sign is positive the response increases when the factor is increased and vice versa [17]. It can be inferred from equation (1) that with increasing load and sliding distance the wear volume loss increases and with increasing percentage reinforcement the wear volume loss decreases. In order to validate the developed regression equation, residuals versus fits plot was generated through MINITAB software. The plot is shown in Figure 3.
Figure 3: Residual versus Fits

It can be observed from the figure 3, that the most of the points lie in the close proximity of central line. A very few points lie far away from the points which lie in the close proximity of central line. Hence the developed regression model predicts a feasible response for the given set of process parameters. 6.4. Confirmation Experiment In order to validate the regression equation developed to estimate the wear volume loss, confirmation experiments were conducted with following range of parameters and compared with the result generated by multiple linear regression model. Parameters used for the confirmation test are given in Table 6. Comparisons of results generated by regression model and confirmation experiments are given in Table 7.
Table 6: Parameters used in the confirmation test
Test No. 1 2 3 Load, L (N) 20 30 40 Sliding Distance, D(M) 1800 2400 3000 Percentage reinforcement, %C (wt %) 2.5 5.0 7.5

Wear Behaviour of 2024 Al Alloy SiC Gr Hybrid Metal Matrix Composites Prepared by Stir Casting
Table 7:

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Comparison of wear volume loss (mm3) results given by regression model and confirmation Test
Test No. 1 2 3 Confirmation experiment 3.35870 6.99870 5.01240 Regression model 3.25000 6.80400 5.40000 Error 3.34% 2.86% 7.7%

It can be observed from Table 7, that the results of response generated by regression model and results of confirmation experiments had shared a good degree of closeness. Error associated with the developed regression model was found to vary between 3.34 7.7%. Hence the developed regression model is capable of predicting the wear volume loss for given set of process parameters. 6.5. SEM Investigation SEM analysis was carried out to study the influence of process parameters on the wear behaviour of the composites. Specimens were analyzed to find the Wear behaviour including operating wear mechanism.
Figure 4: SEM Micrograph of specimen showing wear grooves

(L = 20N, D = 3000M and %C = 5.0 wt%)

Grooves Sliding direction

Figure 5: SEM Micrograph of specimen showing only wear grooves and mild delamination

(L = 20N, D = 3000M and% C = 7.5 wt%)

In the case of Al-5wt% SiC composite (Fig 4.), the extent of wear reduces, with predominantly wear grooves and little delamination and material removal. In Fig 5, SEM micrograph of 7.5 wt % SiC particles shows only wear grooves and mild delamination, due the higher percentage of SiC particles, which carry the applied load effectively, thus reducing the wear. At higher percentage of

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reinforcements SEM micrograph reveals that the sample has undergone more of shallow groove formation (Figure 6). Gurcan et al [2] had concluded that increasing the percentage of SiC resulted in lesser groove forming tendency. At higher loads the specimens exhibited higher wear volume loss because most of the abrasive particles were penetrated into the surface and the graphite film thereby created more grooves resulting in more material removal through severe plastic deformation. Similar inference was reported by Venkat Prasad et al in the wear study of Al/fly ash/Gr composites. Analysis of means of wear volume loss also reveals that at 40N (Figure 2) load the material had undergone more wear than at lower loads. Similar inference in the analysis of means was observed in the study of dry sliding wear behaviour of aluminium matrix composites reinforced by Be2Al2O3(SiO3)6 conducted by Singh et al [1].
Figure 6: SEM Micrograph of specimen showing more wear grooves

(L = 40N, D = 3000M and %C =7.5 wt %)

7. Conclusions
Based on the analysis of Taguchi design and surface morphology following conclusions were drawn: 1. S/N ratio response analysis revealed that the load was the predominant factor in determining the wear behaviour of the hybrid composites. 2. Analysis of means of raw data also revealed that load had got maximum amount of percentage contribution (50.78%) on determining the wear volume loss of the specimen followed by percentage reinforcement (31.4%) and sliding distance (8.71%) . 3. A linear regression model was generated and used to predict the trends of wear volume loss of the hybrid composites. Comparison of confirmation experiments and regression model proved that the regression model had a good degree of closeness with the confirmation experiments. 4. SEM investigations revealed that the major wear mechanism undergone was abrasive wear formation. At higher loads the composites exhibited more amounts of grooves than at lower loads due to particles penetration in to the matrix surface. 5. Analysis of main effects plot also revealed that wear volume loss increases with increasing load and sliding distance and decreases with increasing percentage reinforcement.

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