Mathematical Modeling and Analysis of Tribological Properties of AA6063 Aluminum Alloy Reinforced with Fly Ash by Using Response Surface Methodology

Abstract

Lightweight, high-strength metal matrix composites have attracted considerable interest because of their attractive physical, mechanical and tribological properties. Moreover, they may offer distinct advantages due to good strength and wear resistance. In this research, AA6063 was reinforced with FA particles using compocasting methods. The effects of fly ash content, load, sliding speed and performance tribology of AA6063 –FA composite were evaluated. Dry sliding wear tests were carried out according to experimental design using the pin-on-disc method with three different loads (24.5, 49 and 73.5 N) and three speeds (150, 200 and 250 rpm) at room temperature. Response surface methodology (RSM) was used to analyze the influence of the process parameters on the tribological behavior of the composites. The surface plot showed that the wear rate increased with increasing load, time and sliding velocity. In contrast, the friction coefficient decreased with increasing these parameters. Optimal models for wear rate and friction coefficient showed appropriate results that can be estimated, hence reducing wear testing time and cost.

Research Summary on the Processing, Mechanical and Tribological Properties of Aluminium Matrix Composites as Effected by Fly Ash Reinforcement

“…Wear resistance of the commercial Al significantly improved with inclusion of FA particles and the wear resistance of the composites was much superior to the aluminum without reinforcement across the board for the load range tested dry sliding conditions [102]. This may be as a result of the favourable effect of the FA particles which was a prevailing factor that affected the wear resistance [103]. However, the inclusion of 20 wt.% FA particle to the Al was very effective in promoting wear loss reduction [84].…”

Application of General Full Factorial Statistical Experimental Design’s Approach for the Development of Sustainable Clay-Based Ceramics Incorporated with Malaysia’s Electric Arc Furnace Steel Slag Waste

“…In most of statistical experimental design, analysis of variance (ANOVA) method was conducted to evaluate significant effect of operating factors to properties or responses of a particular developed product or application [74][75][76]. In this case, through ANOVA, the significant effects of weight percentage of EAF slag (A) and firing temperature (B) on the responses, such as linear shrinkage, volume shrinkage, water absorption, apparent porosity, bulk density and MOR could be determined, by observing probability value, or also commonly known as 'p-value' upon the analysis.…”

“…In general, the null hypothesis (H0) of ANOVA states that one or more than one operating factors do not cause a significant difference in means of any responses; H0: µ1 = µ2 = … = µa [55,77]. Most researchers have mutually agreed that the p-value has to be equal or smaller than 0.05 so that the operating factors are statistically significant in affecting the investigated response, leading to rejection of the null hypothesis for the ANOVA [71,72,[74][75][76][78][79][80].…”

“…= µ a [55,77]. Most researchers have mutually agreed that the p-value has to be equal or smaller than 0.05 so that the operating factors are statistically significant in affecting the investigated response, leading to rejection of the null hypothesis for the ANOVA [71,72,[74][75][76][78][79][80].…”

Microstructural and Mechanical Characterization of Alloys

“…Another hardening mechanism for metallic alloys significantly influencing the increase in strength properties is the dispersion hardening and precipitation hardening. Strengthening the AA6063 aluminum alloy with fly ash (FA) particles and the production of AA6063-FA composite, as shown by research [3], leads to an increase in wear rate with increasing load, time and sliding velocity and the friction coefficient decreased with increasing these parameters. In the case of AZ91 magnesium alloy aged at different temperatures (T a = 100 to 300 • C) for different durations (t a = 4 to 192 h), the strengthening process was carried out through intermetallic β-Mg17Al12 phase-separated in the matrix α-Mg [4].…”