Silicon Carbide Ceramic Particulate Reinforced AA2024 Alloy Composite - Part I: Evaluation of Mechanical and Sliding Tribology Performance

In this research work, a master batch (comprising of AA2024 alloy, Silicon Nitride (Si3N4) and Graphite particulates) was reinforced by Silicon-Carbide (SiC) ceramic particulates (0–6 wt.-%; at steps of 2%; i.e. four composites samples viz. ASC-0; ASC-2; ASC-4; ASC-6) with the aim of enhancing mechanical and sliding tribology performance. The semi-automatic stir-casting fabrication process was followed as per standard industrial practice in-order-to fabricate the sample plates of the said alloy composites as per design. Thereafter, the sample specimens were prepared via wire EDM cutting followed by polishing over emery paper; as per ASTM standard dimensions and various physical (density and void content), mechanical (tensile strength, flexural strength, impact strength, hardness etc.), sliding tribology performance (steady state sliding wear; ASTM G-99; Pin-on-Disc tribo-meter), thermal (thermal conductivity, Thermo-Gravimetric Analysis (TGA)); thermo-mechanical (Dynamic Mechanical Analysis (DMA)), fracture-analysis, X-ray diffraction (XRD) etc. characterisation were performed and discussed. In Part-1: Physical, mechanical and sliding tribology performances were discussed. The Taguchi design of experiment technique was employed for designing of experimental runs having input controlling parameters like sliding velocity (0.654–2.616 m/s), sliding distance (784.8–3139.2 m), normal load (5–50 N), reinforcement content (0–6 wt.-%) and environment temperature (20–50 °C). The worn surface morphology studies were performed to understand prevalent wear mechanism using Field Emission Scanning Electron Microscope (FESEM) along with Energy-dispersive X-ray spectroscopy (EDS) that reveals elemental composition and its dispersion on the surface. In Part-2: evaluation of characterizations like thermal, thermo-mechanical, fracture-analysis, X-ray diffraction (XRD) etc. were discussed in correlation with mechanical and sliding wear performance. In Part-3: the entire performance data are analysed using hybrid AHP-TOPSIS technique (an MCDM technique; computationally simple and easy to understand) in-order-to rank the composites formulations.