Tribological wear optimization of AlN strengthened with AA2024 composites through Taguchi techniqueABSTRACT
The intent of the existing research was to examine the tribological characteristics of AA2024/Aluminium Nitride (AlN), synthesized through stir casting route (SCR). The composite specimens were developed at various amounts of (0, 5, 10 and 15 wt.%) AlN particles (P). The pin-on-disc (POD) wear tester was used to predict the wear of the proposed Metal Matrix Composites (MMCs). The experiments were performed by considering three variables such as load (LD), sliding velocity (SV) and sliding distance (SD). Taguchi procedure has been applied to propose the plan of experiments and tests were executed as per L16 orthogonal array (OA) layout. Signal-to-noise (S/N) ratio were used to establish the optimal site of variables in order to obtain lesser wear rate (WR) and co-efficient of friction (CF) for the tested composites. The impact of parameters on WR and CF were analyzed by analysis of variance (ANOVA). The examinations found that the ‘LD’ has more dominant factor on WR with a contribution of 75.86%, and the wt.% of P has more influence on CF with a contribution of 75.06%, respectively.
Keywords:
AA2024; AlN particles; Composites; Pin-on-disc; Taguchi technique; ANOVA
1. INTRODUCTION
Wear resistance property is a crucial factor that must be appropriately taken into account for the purpose of creating design components that provide excellent performance for diverse tribological applications [1]. MMCs strengthened with reinforcement particles demonstrated exceptional strength, high hardness, and improved wear performance, which increased its applications in engineering industries [2]. In MMCs, Aluminium (Al), Magnesium (Mg), Titanium (Ti) and Copper (Cu) are considered as the matrix elements [3]. Among them, aluminium and its alloys are an excellent candidate due to its little density, high resistance to corrosion, and superior mechanical characteristics to many applications [4]. It is also frequently utilized as a transport medium because of its less weight and low cost. The inclusion of several hard ceramic reinforcement, such as aluminium oxide (Al2O3), graphene, silicon carbide (SiC), AlN, silicon nitride (Si3N4), zirconium di oxide (ZrO2), fly ash, etc., enhanced the properties [5, 6]. This investigation highlights on Al2024 due to its easy availability and it’s usage for structural purpose in different engineering domains. From this work, it is clearly noticed that lot of research has been carried out on addition of different reinforcements to improve their performance [7].
The wear resistance capability of ceramic particles filled aluminium metal matrix composites (AMMCs) is higher than that of base alloys [8]. SCR is a reliable manufacturing technique for forming composites due to its affordability, easy to operate, and adaptability. In this process can be used to develop the composite by mixing the matrix and reinforcement at an appropriate parameter to eliminate porosity and provide uniform particles distribution [9]. They examined how silicon carbide dispersion in aluminium 2024 affects the material. Silicon carbide reinforcement was found to have a particle size of 20 µm additionally it was given at 0%, 3%, 6%, and 9% weight percentages. SCR is used to finish composites during synthesis and evaluated their mechanical properties. Due to 9 weight percent (wt.%) silicon carbide, the composite material has a hardness of 55.7 HRB, compared to the aluminium alloy’s lower hardness. With 9% silicon carbide, the composite material had higher ultimate tensile strength. This composite can be used as a viable source in components like gears, drive shafts, and brake drums [10]. The hybrid composite material, which contains AA2024 with 4% carbon nanotubes and 2% silicon, has a maximum tensile strength of 308 N/mm2, 84% higher than the unreinforced matrix alloy. Under elevated load the WR and CF remains low [11]. This study examines the effect of ZrO2 reinforcement on LM25 aluminum alloy using the stir casting method. The supplement of ZrO2 (up to 12%) enhanced hardness, tensile strength, and impact resistance while ensuring uniform particle distribution. Microstructural analysis confirmed strong interfacial bonding, and XRD results showed no phase transformation [12].
This research carried out the pin-on-disc experiments for determine the WR of flyash (FA) filled AA2024 composites developed by stir casting. They concluded that the minor ‘LD’ gives the better wear resistance and also the higher ‘LD’ provide the extensive of wear [13]. This work attempted the wear test of AA6061 composites incorporated with different proportions of AlN particles and the results found that the WR dramatically reduced with an raise in wt.% of AlN and improved with an augment in ‘LD’ and ‘SV’ [14]. They used the Taguchi approach for optimizing the wear parameters on SiC inserted LM13 composites. They reported that the ‘LD’ was the most noteworthy on WR and CF [15]. This research predicted the tribological characteristics of ZrO2 reinforced AA8011 matrix composites and they understood that the insertion of reinforcement restricts the wear loss against the load which results in superior resistance to wear [16]. RADHIKA et al. [17] considered the wear behaviour of LM13/AlN composites. Wear behavior of the composite and alloy was evaluated using POD through design of experiments method. Parameters like LD (10, 20, and 30 N), SV (1, 2, and 3 m/s), and SD (500, 1000, and 1500 m) were mixed for three levels. They observed that the WR raised with raise in ‘LD’ and reduced with increase in ‘SD’ and ‘SV’ [17]. They analyzed the WR of Al2O3 filled Al-20Fe-5Cr composites and they stated that the insertion of Al2O3 content provide better wear resistance [18]. This work investigated the tribological properties of rice husk filled Al-Si-Mg composites using Taguchi approach. They noted that the WR was extremely influenced by wt.% of reinforcement trailed by ‘LD’ and ‘SV’ [19]. They performed the review of wear testing for Al alloy composites reinforced with varying types of reinforcement content. They noted the WR reduced with an augment in content because of the addition of reinforcements develop the mechanical mixed layer thus enhanced the wear resistance [20]. They reported the effect of wear control factors on the WR and CF for the AA7075/TiO2 composites using ANOVA. The results showed that load has the most contributed parameters next by sliding distance and velocity [21]. This researcher reported the WR of AA6061-T6 composites filled with TiC and graphite (Gr) and reported the ‘SV’ was crucial factor on WR and CF, trailed by ‘LD’ [22].
In this research, the wear examination of synthesized composites is performed under an LD of 30, 40, and 50 N, SD of 1000, 1500, and 2000 m, and a constant sliding time (ST) of 15 minutes. Significant enhancement in the wear resistance of AA2024/TiB2 with the incorporation of increased reinforcements. As the concentration of TiB2 particles rises, the weight loss (WL) declines. On the other hand, higher applied loads are associated with increased WL in the samples. It is noted that the WL progresses when the LD is raised up from 35–50 N and when the reinforcement is reduced to below 2% by weight [23]. The wear of 2024 hybrid composites is evaluated under LD of (0.5 Kgf, 1.0 Kgf, 1.5 Kgf), a track diameter of 60 mm, and ST of 15, 30, and 45 minutes. The results indicate that wear reduces as the wt.% of FA and SiC increase. On the contrary, wear growths with higher LD and longer ST. Furthermore, the AA2024/hybrid composites exhibit greater wear resistance related to the base AA2024 [24]. This study enhances A356 composites by reinforcing them with boron carbide, graphite and iron oxide using the Taguchi grey relational technique to improve wear resistance. Selective Laser Melting was used for fabrication, significantly enhancing durability and mechanical properties. The optimized wear resistance was observed at 40 N LD, 6 m/s SV, and 1000 m SD. ANOVA results indicate that SV had the highest impact on wear performance [25]. According to the literature, there are so many factors are affecting the wear behaviour of the composites. Hence, the outcome of this work was to identify the effect of control parameters on WR and CF for the AA2024/AlN composites using Taguchi method.
2. MATERIALS AND METHODS
In this experiment, the base material was taken as AA2024 in rod form, with the size of length 8 cm and diameter 3 cm as displayed in Figure 1 and the compositions are depicted in Table 1. AA2024, a high-strength aluminum alloy, is commonly employed in the manufacturing of aircraft structures, such as wings, fuselage and landing gear parts. Additionally, it finds applications in the automotive industry for producing lightweight yet durable components like wheels and suspension systems.
AlN particles (P) with mesh size 40 microns was used as the reinforcement and the physical and scanning electron microscopy (SEM) image is revealed in Figures 2a, b.
The composites were fabricated with inclusion of varying amounts of (0, 5, 10, and 15 wt.%) P by SCR. For the fabrication of composites, the essential amount of sliced AA2024 was stored into a crucible made of graphite and it was heated to 750°C using an electric furnace under the argon gas environment. Meanwhile, the required wt.% of AlN were preheated at 400°C to eliminate the humidity and develop the interfacial bonding. The melt is then mixed with the warmed AlN, and the slurry was continually stirred for 10 minutes with a stirrer speed of 400 rpm [26]. This molten mixture was then filled into a cylindrical die of dimension 150 mm length and 25 mm diameter. Figure 3 displays the entire work flow of the present research.
The created composites were processed and sized into the required dimensions as per ASTM G 99. The wear test was performed using a Ducom POD Tester arrangement as in Figure 4. The wear test pins of size 10 mm diameter and 30 mm length were created using the wire electrical discharge machining process and it was fixed against the EN31 grade steel disc with 62 HRC. Prior testing, the test pins were polished by the emery sheet to ensure adequate contact with the counterface. In the dry sliding wear tests, there are several variables are involved. Based on the earlier studies, the wear rate mainly controlled by the factors are P, LD, SV and SD [20, 27]. Therefore, these four factors are engaged as the input factors and its levels are presented in Table 2. The tests were performed as per L16 OA layout as shown in Table 3. The weight loss before and after the tests was taken using the electronic balance equipment. According to a standard formula, the WR and CF were determined [28]. The test results were changed into a S/N ratio using Taguchi technique. There are three S/N ratios are accessible depending upon the performance characteristics [29]. Since we need the lower WR and CF, hence the lower-the-better S/N ratio was used in this study. ANOVA was applied to study the significance of the parameters used [30]. Table 3 depict the responses and their computed S/N ratios.
3. RESULTS AND DISCUSSIONS
3.1. Impact of parameters on wear rate
Figure 5 displays the S/N ratio graph of WR. From the figure, the impact of parameters such as P, LD, SV and SD on WR of the proposed AA2024/AlN composites was noticed. It was revealed that the WR slowly decreased with increase in wt.% of P from 5 wt.% to 15 wt.%. Here, the better wear resistance exhibited in 15 wt.% of AlN reinforcements. Meanwhile, the higher ‘LD’ condition increased the WR due to more contact between the surfaces thus lead to develop the maximum WR at 20 N of ‘LD’. The reason was that the applied ‘LD’ create high pressure on the work specimen thus leads to increase the friction which results in removal of more materials from the pin surface. But, the ‘SV’ and ‘SD’ are less important factor for influencing the WR. The initial level of ‘SV’ gives less WR, after that it is slightly increased at 1.0 m/s of ‘SV’. Similarly, the ‘SD’ increased from 400 m to 1600 m the WR slowly decreased.
The value of S/N ratio for WR is shown in Table 4. In the table, we noticed the order of noteworthy factors on WR is indicated by delta value. It is clearly found that ‘LD’ was the main impact factor on WR trailed by ‘P’ and ‘SV’. It can be also noted that the optimum setting of control parameters for attain the less WR are ‘P’ of 15 wt.%, ‘LD’ of 5 N, ‘SV’ of 2.0 m/s and ‘SD’ of 800 m, respectively. The results of ANOVA is provided in Table 5. It can be ensured that the ‘LD’ has the most impact factor with contribution of 75.86%, next by ‘P’ with contribution of 22.03%. The ‘SV’ and ‘SD’ were indicated as the less significant factors on WR with contributions are 0.43% and 0.70%, respectively.
Figures 6a–c shows the contour plots of WR with related to control parameters. The interactive effect of load versus wt.% of AlN on WR is depicted in Figure 6a. It is clearly revealed that the WR decreased with an improve in AlN content. However, an increasing in ‘LD’ increase the WR drastically. The elevated WR exhibited in 20 N of ‘LD’ and AlN composition up to 5 wt.%. In meantime, the higher amount of AlN reinforced composites produced less WR at initial level of ‘LD’. Furthermore, the WR slowly improved with increasing trends in ‘LD’ at all level of AlN compositions.
In Figure 6b reveals the impact of ‘SV’ and wt.% of AlN on WR. It can be noticed that the WR increases with a raise in ‘SV’. But, the insertion of AlN effectively reduced the WR due to higher hardness. Here, the lower WR of 0.030 mm3/m acquired in 15 wt.% of AlN reinforcements by 2 m/s of ‘SV’. Meanwhile, the 5 wt.% of AlN composite gives more WR by the ‘SV’ of 1.5 m/s. In Figure 6c illustrate the effect of AlN wt.% and ‘SD’ on WR. It is obviously showed that the WR dramatically reduced with an increased in AlN particles at all level of ‘D’. Moreover, the maximum WR of 0.105 mm3/m attained in 4 wt.% AlN composites at a ‘D’ of 750 m.
3.2. Impact of parameters on CF
The S/N ratio and means graph for CF is depicted in Figure 7. From the graph, we understand the individual impact of factors such as P, LD, SV and SD on CF for the tested composites. According to the graphs as in figure, it is exactly found that the addition of AlN reinforcements significantly reduced the CF.
Moreover, the quantity of AlN augmented from 5 wt.% to 15 wt.%, the CF gradually decreased. Hence, the less CF exhibited in 15 wt.% AlN reinforced MMCs. Similarly, the lower level of ‘LD’ (5 N) provide less CF after that it is slowly improved at 10 N of ‘LD’. But the CF slowly declined with raise in ‘LD’ from 15 N to 20 N. By considering the ‘SV’, the less CF achieved in 1.5 m/s of ‘SV’, thereafter it is slightly improved. The lower setting of ‘SD’ gives low CF then it is gradually increased from 800 m to 1600 m, respectively. Table 6 illustrate S/N ratio value of CF. In the table, we understood the order of impact factors on CF is denoted by delta value. It is obviously revealed that ‘P’ was the major dominant factor on CF subsequently by ‘LD’ and ‘SD’. It can be also noted that the optimum setting of parameters for attain the less CF are ‘P’ of 15 wt.%, ‘LD’ of 5 N, ‘SV’ of 1.5 m/s and ‘SD’ of 800 m. The ANOVA result for CF is depicted in Table 7. It clearly evident that the ‘P’ has play a major role for controlling the CF with contribution of 75.06%, trailed by ‘LD’ and ‘SD’ with contributions is 10.34% and 10.01%, respectively. The ‘SV’ was represented as the insignificant factor on CF with contribution of 1.75% only.
The contour plot of COF is shown in Figures 8a–c. From the plots, it is clear that the interaction effect of parameters such as P, LD, SV and SD on CF for the synthesized composites is seen. In Figure 8a shows the effect of ‘P’ and ‘LD’ on the CF and it is showed that CF gradually abridged with an raise in ‘P’ from 5 wt.% to 15 wt.% at 5 N of ‘LD’. Furthermore, the CF linearly raised when an increased in ‘L’ from 5 N to 20 N. The minimum CF of 0.42 is demonstrated in 15 wt.% AlN reinforcements at 5 N of ‘LD’. But, the high CF (0.70) produced at 20 N of ‘LD’ by unreinforced alloy. The effect of ‘SV’ and ‘P’ on CF is illustrates in Figure 8b. It has been explored that the higher amount of ‘P’ inclusion with higher ‘SV’ provide less CF. The addition of AlN particles resists the friction against the ‘LD’ which results in decrease the CF. The higher CF attained at 2 m/s of ‘SV’ by the base alloy. So that, the CF significantly reduced at all level of ‘SV’ for AlN reinforced composites. In Figure 8c demonstrates the impact of ‘P’ and ‘SD’ on the CF and it has noticed that the low level of ‘SD’ produced less CF for the 15 wt.% of AlN composite. The augment in ‘SD’ from 500 m to 1500 m increase the CF. and the moderate range of CF developed in 5 wt.% AlN filled composite at ‘SD’ of 800 m.
4. CONCLUSIONS
The AA2024 matrix composites were successfully proposed via stir casting by inclusion of varying amounts of AlN particles. The tribological properties of the prepared composites were studied by dry sliding wear test and the Taguchi technique has been used to predict the WR and CF. The S/N ratio results showed that the less WR exhibited in 15 wt.% of AlN reinforced composite at the ‘LD’ of 5 N, ‘SV’ of 0.5 m/s and ‘SD’ of 1600 m. Similarly, the minimum CF gained in 15 wt.% of AlN reinforcements at the ‘LD’ of 5 N, ‘SV’ of 1.5 m/s and ‘SD’ of 800 m. The ANOVA results stated that the ‘LD’ was the most notable factor on WR next by wt.% of AlN with contributions of 75.86% and 22.03%, respectively. Meanwhile, the wt.% of AlN has the primary contribution (75.06%) factor on CF followed by ‘LD’ (10.34%). Thus, these composites are preferable and makes it appropriate for use in transportation and structural parts in various engineering fields.
5. ACKNOWLEDGMENTS
This project was supported by Researchers Supporting Project number (RSPD2025R1103), King Saud University, Riyadh, Saudi Arabia.
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Publication Dates
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Publication in this collection
04 Apr 2025 -
Date of issue
2025
History
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Received
26 Nov 2024 -
Accepted
19 Feb 2025
