Evaluation of Copper-Based Alloy (C93200) Composites Reinforced with Marble Dust Developed by Stir Casting under Vacuum Environment

Abstract

Copper-based alloy (C93200) composites reinforced with a different weight percentage of marble dust particles (1.5, 3, 4.5, and 6 wt.%) were developed by stir casting method under vacuum environment. By using this type of reinforcement, it was possible to detect a suitable material for bearing applications. The manufactured material was characterized for its mechanical properties using a micro-hardness tester. A universal INSTRON-5967 machine was used to detect the yield and tensile strength. Further the hardness features were measured using a Walter Uhl model machine, whereby the wear characteristics were simulated under the pin-on-disc tribometer under different working conditions in ambient temperature (23 °C). Next, the preference selection index (PSI) technique that considers multi-criteria decision-making was proposed to validate which material was the best candidate. For the selection of material criteria, some specific material intrinsic properties—such as, density, void fraction, hardness resistance along with tensile, compressive, and flexural strength—were proposed and the surface characteristics linked to friction coefficients along wear properties. It was found that the novel composite material containing 4.5 wt.% of marble dust provided the best combination of properties and is a suitable candidate material for bearing applications.

Preliminary evaluations on development and material selection of high temperature vacuum casted marble dust-reinforced silicon-bronze alloy material for bearing applications

“…A similar trend was seen in study of Rajak et al., which showed that MD addition decreases wear rate in copper alloy-based composites. 11 Figure 7 describes the influence of MD addition on the PDC-9 (wear rate at 5 N), PDC-10 (wear rate at 15 N), PDC-11 (wear rate at 25 N) and PDC-12 (wear rate at 35 N) of the developed bearing materials. It was observed from Figure 7 that the specific wear rate decreased continuously with increasing normal loading from 5 N to 25 N. With increase in loading value and MD addition, the actual contact surface area increases causing the reduction in applied load between the two contacting surfaces and thus the specific wear rate was decreased.…”

“…4.5 wt.%), the coefficient of friction and wear performance improves considerably. 11 Gangwar et al. fabricated quicklime (CaO) reinforced silicon-bronze alloy composites by varying the weight percentages as 0, 2.5, 5, 7.5 and 10 for bearing material employing high temperature vacuum casting machine.…”

A critical review on tribological properties, thermal behavior, and different applications of industrial waste reinforcement for composites

“…MD reinforcement of 4.5 wt % was chosen as the best alternative automotive application. 37 The automobile elements consist of rotating machine parts involving effective utilization of rolling element bearings. The inappropriate selection of materials may result in the failure of bearings that can further increase the cost and lead time.…”

“…The decrease in wear loss (improved wear performance) is attributed to an adequate reinforcement bonding between the copper matrix alloy and hard marble dust particles that resulted in higher hardness of composites. 37 Ray et al studied the wear behavior of glass epoxy hybrid composite reinforced with varying weight percent values (0, 5, 10, 15 wt%) of MD. With the help of Taguchi experimental trials and ANN prediction, it was found that there is a strong correlation between different control factors and erosion wear behavior, and optimal settings was predicted for minimum wear loss.…”

“…The decrease in wear loss (improved wear performance) is attributed to an adequate reinforcement bonding between the copper matrix alloy and hard marble dust particles that resulted in higher hardness of composites. 37 Ray et al. studied the wear behavior of glass epoxy hybrid composite reinforced with varying weight percent values (0, 5, 10, 15 wt%) of MD.…”