A Study of Porosity Effect on Tribological Behavior of Cast Al A380M and Sintered Al 6061 Alloys
Affiliation(s)
Department of Process Engineering and Applied Science, Materials Engineering Program, Dalhousie University, Halifax, Canada.
Department of Process Engineering and Applied Science, Materials Engineering Program, Dalhousie University, Halifax, Canada.
ABSTRACT
Due to their light weight, high corrosion resistance and good heat conductivity, aluminium alloys are used in many industries today. They are suitable for manufacturing many automotive components such as clutch housings. These alloys can be fabricated by powder metallurgy and casting methods, in which porosity is a common feature. The presence of pores is responsible for reducing their strength, ductility and wear resistance. The present study aims to establish an understanding of the tribological behavior of high pressure die cast Al A380M and powder metallurgy synthesized Al 6061. In this study, dry sliding wear behavior of Al A380M and Al 6061 alloys was investigated under low loads (1.5 N – 5 N) against AISI 52100 bearing steel ball using a reciprocating ball-on-flat configuration and frequency of 10 Hz. Wear mechanisms were studied through microscopic examination of the wear tracks. This study revealed that due to combined effect of real area of contact and subsurface cracking, wear rate increased with increasing porosity content. The difference in friction and wear behavior between received Al A380M and Al 6061 is attributed to their hardness differences.
Due to their light weight, high corrosion resistance and good heat conductivity, aluminium alloys are used in many industries today. They are suitable for manufacturing many automotive components such as clutch housings. These alloys can be fabricated by powder metallurgy and casting methods, in which porosity is a common feature. The presence of pores is responsible for reducing their strength, ductility and wear resistance. The present study aims to establish an understanding of the tribological behavior of high pressure die cast Al A380M and powder metallurgy synthesized Al 6061. In this study, dry sliding wear behavior of Al A380M and Al 6061 alloys was investigated under low loads (1.5 N – 5 N) against AISI 52100 bearing steel ball using a reciprocating ball-on-flat configuration and frequency of 10 Hz. Wear mechanisms were studied through microscopic examination of the wear tracks. This study revealed that due to combined effect of real area of contact and subsurface cracking, wear rate increased with increasing porosity content. The difference in friction and wear behavior between received Al A380M and Al 6061 is attributed to their hardness differences.
Cite this paper
Sinha, A. and Farhat, Z. (2015) A Study of Porosity Effect on Tribological Behavior of Cast Al A380M and Sintered Al 6061 Alloys. Journal of Surface Engineered Materials and Advanced Technology, 5, 1-16. doi: 10.4236/jsemat.2015.51001.
Sinha, A. and Farhat, Z. (2015) A Study of Porosity Effect on Tribological Behavior of Cast Al A380M and Sintered Al 6061 Alloys. Journal of Surface Engineered Materials and Advanced Technology, 5, 1-16. doi: 10.4236/jsemat.2015.51001.
References
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[1] Anand, S., Srivatsan, T.S., Wu, Y. and Lavernia, E.J. (1997) Processing, Microstructure and Fracture Behaviour of a Spray Atomized and Deposited Aluminum-Silicon Alloy. Journal of Materials Science, 32, 2835-2848.
http://dx.doi.org/10.1023/A:1018668332318 [2] Zhou, J., Duszczyk, J. and Korevaar, B.M. (1991) As-Spray-Deposited Structure of an Al-20Si-5Fe Osprey Perform and Its Development during Subsequent Processing. Journal of Materials Science, 26, 5275-5291.
http://dx.doi.org/10.1007/BF01143222 [3] Prasad, B.K., Venkateswarlu, K., Modi, O.P., Jha, A.K., Das, S., Dasgupta, R. and Yegneswaran, A.H. (1998) Sliding Wear Behavior of Some Al-Si Alloys: Role of Shape and Size of Si Particles and Test Conditions. Metallurgical and Materials Transactions, 29A, 2747-2752. http://dx.doi.org/10.1007/s11661-998-0315-7 [4] Shivanath, R., Sengupta, P.K. and Eyre, T.S. (1977) Wear of Aluminium-Silicon Alloys. The British Foundrymen, 70, 349-356. [5] Yassen, R.S. and Dwarakadasa, E.S. (1983) Wear of Aluminium under Dry Sliding Conditions. Wear, 84, 375-379.
http://dx.doi.org/10.1016/0043-1648(83)90277-6 [6] Min, K.H., Kang, S.P., Kim, D.G. and Kim, Y.D. (2005) Sintering Characteristic of AlO3-Reinforced 2xxx Series Al Composite Powders. Journal of Alloys Compounds, 400, 150-153. http://dx.doi.org/10.1016/j.jallcom.2005.03.070 [7] ASM and Klar, E. (1984) ASM Metal Handbook Vol. 7: Powder Metallurgy. 9th Edition, ASM International, Almere. [8] Zhen, L. and Kang, S.B. (1997) Deformation and Fracture Behavior of Two Al-Mg-Si Alloys. Metallurgical and Materials Transactions, 28A, 1489-1497. http://dx.doi.org/10.1007/s11661-997-0211-6 [9] Clegg, A.J. and Das, A.A. (1997) The Influence of Structural Modifiers on the Refinement of the Primary Silicon in a Hypereutectic Aluminium Silicon Alloy. The British Foundryman, 70, 56-63. [10] Molins, R., Bartout, J.D. and Beivenu, Y. (1991) Microstructural and Analytical Characterization of Al2O3 Composite Interfaces. Materials Science and Engineering A, 135, 111-117. http://dx.doi.org/10.1016/0921-5093(91)90546-Y [11] Nussbaum, E.D. (1997) Semi-Solid Forming of Aluminium and Magnesium. Light Metal Age, 57, 54-58. [12] Aylor, D.M. and Moren, P.J. (1985) Corrosion Behavior of Cast Aluminium Matrix Composites in Chloride Media. Journal of the Electrochemical Society, 132, 277. [13] Zeuner, T., Stojanov, P., Sahm, P.R., Ruppert, H. and Engels, A. (1998) Developing Trends in Disc Brake Technology for Rail Application. Materials Science and Technology, 14, 857-863. http://dx.doi.org/10.1179/mst.1998.14.9-10.857 [14] Proudhon, H., Savkova, J., Basseville, S., Guipont, V., Jeandin, M. and Cailletaud, G. (2014) Experimental and Numerical Wear Studies of Porous Reactive Plasma Sprayed Ti-6Al-4V/TiN Composite Coating. Wear, 311, 159-166.
http://dx.doi.org/10.1016/j.wear.2014.01.012 [15] Zhang, L., Qu, X.H., Duan, B.H., He, X.B. and Qin, M.L. (2008) Effect of Porosity on Wear Resistance of SiCp/Cu Composites Prepared by Pressureless Infiltration. Transactions of Nonferrous Metals Society of China, 18, 1076-1082.
http://dx.doi.org/10.1016/S1003-6326(08)60184-3 [16] Chen, Q., Li, D. and Cook, B. (2009) Is Porosity Always Detrimental to the Wear Resistance of Materials?—A Computational Study on the Effect of Porosity on Erosive Wear of TiC/Cu Composites. Wear, 267, 1153-1159.
http://dx.doi.org/10.1016/j.wear.2008.12.058 [17] Simchi, A. and Danninger, H. (2004) Effects of Porosity on Delamination Wear Behaviour of Sintered Plain Iron. Powder Metallurgy, 47, 73-80. http://dx.doi.org/10.1179/003258904225015545 [18] Dubrujeaud, B., Vardavoulias, M. and Jeandin, M. (1994) The Role of Porosity in the Dry Sliding Wear of a Sintered Ferrous Alloy. Wear, 174, 155-161. http://dx.doi.org/10.1016/0043-1648(94)90097-3 [19] Li, D.Y. and Luo, Y.C. (2001) Effects of TiN Nano-Particleson Porosity and Wear Behaviour of TiC/TiNi Tribo Composite. Journal of Materials Science Letters, 20, 2249-2252. [20] Hamid, A.A., Ghosh, P., Jain, S. and Ray, S. (2006) Influence of Particle Content and Porosity on the Wear Behaviour of Cast in Situ Al(Mn)-Al2O3(MnO2) Composite. Wear, 260, 368-378. http://dx.doi.org/10.1016/j.wear.2005.02.120 [21] Sarikaya, O. (2005) Effect of Some Parameters on Microstructure and Hardness of Alumina Coatings Prepared by the Air Plasma Spraying Process. Surface and Coatings Technology, 190, 388-393.
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