Tribological characterization of Al6061/alumina/graphite/redmud hybrid composite for brake rotor application

Kumar, Mukesh; Megalingam, A.

doi:10.1080/02726351.2017.1367747

Cited by 40 publications

(12 citation statements)

References 35 publications

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“…Raju et al. 29 and Kumar and Megalingam 50 have also published similar reports indicating that addition of solid lubricants (in addition to ceramic reinforcements) improves the wear resistance of Al-based composites. This may be attributed to the self-lubricating properties of these composites that further results in formation of a protective surface layer on the wear surface of hybrid composites during the wear test.…”

Section: Results and Analysismentioning

confidence: 78%

Investigations on dry sliding frictional and wear characteristics of SiC and red mud reinforced Al2024 matrix hybrid composites using Taguchi's approach

Singh

Chauhan

2018

Proceedings of the IMechE

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In this study, frictional and wear behavior of Al2024/SiC/red mud hybrid composites processed by stir casting route has been investigated under dry sliding conditions. Further, influence of parameters, namely red mud fraction (5–20 wt%) and particle size (37–125 µm), applied load (10–40 N), sliding distance (3000–6000 m), sliding velocity (0.5–2.0 m/s), and their interaction terms on multiresponse characteristics has been examined by employing Taguchi's approach. The wear behavior of hybrid Al composites has been investigated using pin-on-disc apparatus at room temperature and optimization of parameters has been carried by statistical analysis. The adequacy of the developed model has been checked by conducting confirmation experiment and studying the worn surface morphology. The analysis of variance indicates that sliding distance has highest influence (with a contribution of 19.74%) on the wear loss characteristics, while applied load has a maximum contribution of 38.86% in the friction coefficient of the hybrid composites. It has also been revealed that the wear resistance of the hybrid composites is improved with an increase in red mud fraction and decrease in the magnitude of applied load and sliding distance. The morphology of worn surfaces shows that ploughing and abrasion of the wear surface is considerably increased with an increase in the magnitude of wear parameters. But, an increase in red mud fraction reduces the plastic deformation (delamination) of the wear surface since it favors formation of a protective layer between the sliding surfaces. The results of the confirmation experiment indicate that wear loss and friction coefficient of the developed composites have been reduced by 400 and 51%, respectively, in comparison to unreinforced alloy under optimized conditions. The errors in the measurements of the wear loss and friction coefficient have been found to be 4.26 and 2.63%, respectively.

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Section: Results and Analysismentioning

confidence: 78%

Investigations on dry sliding frictional and wear characteristics of SiC and red mud reinforced Al2024 matrix hybrid composites using Taguchi's approach

Singh

Chauhan

2018

Proceedings of the IMechE

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“…Kumar and Megalingam [42] have developed Al6061 based hybrid composites containing 3 wt.% of Al 2 O 3p percentage, 3 wt.% of Gr p percentage and (3-11 wt.%) of RM content using casting route. It has been noticed that the hardness of the Al6061 based composites is increased with addition of 3 wt.% of Al 2 O 3 particles, while it reduces with an increase in reinforcement fraction of RM particles.…”

Section: Microstructure and Mechanical Propertiesmentioning

confidence: 99%

“…The study indicates that the plastic strain and sub-surface deformation of the composites increases with increasing sliding time and applied load and this phenomenon has been considerably reduced with addition of hybrid reinforcements. Kumar and Megalingam [42] have noticed that inclusion of RM particles improves abrasion resistance of the Al6061/Al 2 O 3 /Gr hybrid composites irrespective of the magnitude of applied load. The wear tests were conducted on a pin-on-disc monitor and EN 32 steel disc was used as a counterface material.…”

Section: Wear Propertiesmentioning

confidence: 99%

A review of microstructure, mechanical properties and wear behavior of hybrid aluminium matrix composites fabricated via stir casting route

Singh

Chauhan

2019

Sādhanā

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This article focuses on the mechanical and wear properties of the Al-based hybrid composites fabricated by stir casting route. A wide range of literature has been consulted in this regard and it has been revealed that processing conditions can be tailored to obtain homogeneous structure of the Al-composites. The addition of ceramic particles has been found to be essential to provide requisite strength and hardness to these composites. Also, use of agro/industrial waste materials such as fly ash, red mud and rice husk ash as a complementary reinforcement reduces the density of the hybrid composites without compromising the mechanical properties. The literature review also indicates that addition of soft reinforcements along with hard reinforcements reduces the brittleness of the hybrid composites. Moreover, the presence of solid lubricants like graphite significantly improves the wear resistance of these materials. It has been noticed that incorporation of solid lubricants also helps in the formation of a protective tribolayer at the interface thereby reducing the wear rate and plastic deformation of these composites. In overall, study concludes that Al-based hybrid composites have great promise to serve as a substitute to the ceramic reinforced composites and the unreinforced Al-alloys in various automotive applications requiring low cost, high strength-to-weight ratio and superior wear resistance.

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“…The wear rate of the composited reduced exhibiting better wear resistance of the MMCs. Kumar et al [14] studied the effects of weight fraction of red mud particles on dry sliding wear behaviour of Al6061/Alumina/Graphite hybrid metal matrix composites. They found that wear resistance of 11 wt% of red mud particles was enhanced by about 90% when compared to that of Al6061 hybrid MMCs.…”

Section: Introductionmentioning

confidence: 99%

Dry sliding wear behavior of Al 6082 metal matrix composites reinforced with red mud particles

2020

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The present study aims at investigating the dry sliding wear behavior of Al-based 6082 metal matrix composites (AMMCs) reinforced with red mud particles by pin-on-disc configuration. AMMCs were fabricated with three different weight fractions of red mud particles ranging from 2 to 6% by using the stir-casting method. The friction coefficients and volumetric wear rates were continuously evaluated under normal loads of 10-30 N and sliding speed of 1.5 m s −1 for the constant sliding distance of 1000 m. Microstructural analysis indicated that red mud particles are more or less uniformly dispersed throughout the Al matrix with minimal agglomeration. Experimental data shows that microhardness and tensile strengths of both the as-cast and heat-treated composites are steadily improved by increasing the amount of reinforced red mud particles but at the cost of ductility. Analysis of worn surfaces revealed that delamination and abrasion are dominant wear mechanisms for the case of the heat-treated composites are whereas the adhesion wear mechanism for the base alloy. The composite containing 4% red mud particles experienced the lowest wear rate at a normal load of 30 N and sliding speed of 1.5 m s −1 as compared to other composites including the base alloy. While the composite with 2% red mud particles shows the lowest friction coefficient, base alloy exhibited the highest friction coefficient.

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Tribological characterization of Al6061/alumina/graphite/redmud hybrid composite for brake rotor application

Cited by 40 publications

References 35 publications

Investigations on dry sliding frictional and wear characteristics of SiC and red mud reinforced Al2024 matrix hybrid composites using Taguchi's approach

Investigations on dry sliding frictional and wear characteristics of SiC and red mud reinforced Al2024 matrix hybrid composites using Taguchi's approach

A review of microstructure, mechanical properties and wear behavior of hybrid aluminium matrix composites fabricated via stir casting route

Dry sliding wear behavior of Al 6082 metal matrix composites reinforced with red mud particles

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