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Optimization of Fretting Wear Parameters and Effect of High Temperature on Fretting Wear Behavior of Al6061 Alloy and Al6061-SiC Composite

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Abstract

Objectives

Al 6061 alloys are being used in vast industrial applications. The dry sliding wear behavior of SiC based Al6061 composites has been thoroughly explored in recent decade while its fretting wear behavior at high temperatures has not been studied well. In this work, the fretting wear parameters of Al6061 alloy and Al 6061 reinforced with 2 wt% SiC have been optimized and high temperature fretting wear behavior analyzed.

Methods

Ultrasonic assisted stir casting method has been employed to prepare Al6061-2SiC composite. Integrated Taguchi and TOPSIS methods have been used to optimize the input parameters viz. temperature, material type, applied load, time and frequency of strokes.

Results

It is observed that out of temperature, applied load, time and frequency of strokes, temperature proves out to be the most critical parameter affecting the wear behavior of the matrix alloy and its composite the most. Through integrated Taguchi and TOPSIS optimization technique, it is found that the most optimal combination of parameters for minimal wear rate and friction coefficient is Al6061 + 2 wt% SiC composite at 200 N load, 100 °C temperature, 10 min time, and 40 Hz frequency of fretting strokes.

Conclusions

The microscopic analysis of the samples revealed that fretting wear operates in partial slip regime in the composite tested at optimum combination of parameters. Wear regime changes from partial slip to mixed fretting with rise in temperature in the composite. In the alloy, the transition from mixed fretting to gross slip regime takes place with the rise in temperature. Al6061 alloy reinforced with 2 wt% SiC at optimum combination of parameters can prove to be a good replacement of conventional materials used in machinery prone to fretting wear.

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Acknowledgments

The authors would like to thank the staff of the foundry laboratory of the Department of Metallurgical and Materials Engineering NIT Srinagar for their help in the fabrication of composites. They would also like to thank colleagues and friends for their unconditional support for the realization of this project.

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Authors and Affiliations

  1. Mechanical Engineering Department, National Institute of Technology Srinagar, Srinagar, J & K, 190006, India

    Mehak Nisar & M. S. Charoo

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  1. Mehak Nisar
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  2. M. S. Charoo
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Contributions

Conceptualization: [Mehak Nisar]; Methodology: [Mehak Nisar]; Formal analysis and investigation: [Mehak Nisar]; Writing - original draft preparation: [Mehak Nisar]; Writing - review and editing: [Mehak Nisar]; Supervision: [Dr. M. S. Charoo].

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Correspondence to M. S. Charoo.

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Nisar, M., Charoo, M.S. Optimization of Fretting Wear Parameters and Effect of High Temperature on Fretting Wear Behavior of Al6061 Alloy and Al6061-SiC Composite. Silicon 14, 3949–3961 (2022). https://doi.org/10.1007/s12633-021-01172-7

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