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Modelling of Dry Sliding Wear Performance of Al-WC Nanocomposites

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Abstract

In this study, modelling of specific wear rate and worn surface roughness of Al-WC nanocomposites is attempted. For fabrication of Al-WC nanocomposites, the liquid metallurgy-based ex situ method is exercised. A tailored casting unit with ultrasonic vibration and mechanical stirrer setup is used for fabrication. As particulates are of nanosize, the maximum amount of reinforcement is restricted at 2wt.%. Tribological tests are executed on a pin-on-disc type tribotester. Surface roughness (Ra) of the tested surfaces is measured using a dedicated surface roughness tester. A design of experiment using the central composite design method has been prepared considering input parameters as wt.% of reinforcements (1%, 1.5%, and 2%), the load applied on tribological tests (10, 20, and 30N), and sliding speed (0.1, 0.2, and 0.3 m/s). Specific wear rate and Ra values of worn out surfaces are considered as output responses of this study. A second-order regression model is developed using experimental design method. The response surface method (RSM) is employed for this purpose. ANOVA is performed on the experimental results. Wt.% of reinforcement becomes the most significant parameter for specific wear rate. In the case of the Ra value, load (B) is the most significant parameter with a 58.63% level of significance. After performing a fresh set of experiments and fitting the results into the developed model, it is observed that the difference between actual results and predicted results is within a permissible range. Modelling has been attempted in this work to conclude wear performance of newly developed stir-cast Al-WC nanocomposites with minimum number of experiment. SEM micrographs and EDAX spectrum of wear debris collected from the worn surface are also attempted in the end. Formation of a mixed layer is confirmed which helps to develop better wear performance in composites with more WC as reinforcement. No sign of major ploughing or groove formation is observed.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Swami Vivekananda Institute of Science and Technology, Kolkata, India

    Ranjit Kumar Das

  2. Department of Mechanical Engineering, Jadavpur University, Kolkata, India

    Ranjit Kumar Das, Suswagata Poria & Prasanta Sahoo

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  1. Ranjit Kumar Das
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  2. Suswagata Poria
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Das, R.K., Poria, S. & Sahoo, P. Modelling of Dry Sliding Wear Performance of Al-WC Nanocomposites. J. Inst. Eng. India Ser. D 105, 461–475 (2024). https://doi.org/10.1007/s40033-023-00494-7

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