Wear Behaviour Analysis of Heat Treated A356 Composite with Copper and Copper-Coated Zinc as Reinforcements

Nithesh, K.; Sathyashankara, Sharma; Rajesh, Nayak; GowriShankar, M.C.; Karthik, B.M.; Doddapaneni, Srinivas

doi:10.1590/1980-5373-MR-2023-0225

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Articles • Mat. Res. 26 • 2023 • https://doi.org/10.1590/1980-5373-MR-2023-0225 copy

Wear Behaviour Analysis of Heat Treated A356 Composite with Copper and Copper-Coated Zinc as Reinforcements

Authorship SCIMAGO INSTITUTIONS RANKINGS

The present study reflects on the wear behaviour characteristics of A356 composite with trace addition of copper and copper-coated zinc as reinforcements. Dry sliding wear tests were conducted on fabricated as-cast and heat treated composites by varying load of 20-60 N under constant sliding speed of 1 m/s and sliding distance of 3000 m. Results confirmed that copper-coated zinc was successfully introduced as reinforcement into A356 matrix using two-step casting method. Scanning Electron Microscope (SEM) images confirmed the presence and homogeneous distribution of the added reinforcements in the matrix. T6 treatment with addition of Cu reinforcement facilitated age hardening showing 121% hardness improvement compared to as-cast matrix A356. At lower loads, wear results showed 117-134% enhanced wear resistance in composite reinforced with 1 wt.% Cu and aging at 100°C. However at higher loads, 153-210% improvement in wear resistance was observed. Overall, copper and Cu-coated zinc reinforced composite along with T6 treatment exhibited significant improvement in hardness wear property compared to as-cast matrix A356 alloy.

Keywords:
A356 alloy; Aluminum Matrix Composite (AMC); Age hardening; Copper-coated zinc reinforcements

Alloy Composition	A	C1	C2
Magnesium (wt.%)	1	1	1
Copper (wt.%)	0	0.5	1
Zinc (wt.%)	0	0.5	0

Load (N)	Sliding Distance (m)	Mass loss method							System generated
		Mass loss Δm (m1-m2) (mg)			Speed (RPM)	Wear rate W_r (10^-5 mm³/m)			Wear (µm)
		A (as-cast)	A (aged at 100°C)	A (aged at 200°C)	Speed (RPM)	A (as-cast)	A (aged at 100°C)	A (aged at 200°C)	A (as-cast)	A (aged at 100°C)	A (aged at 200°C)
20	500	0.8	0.6	0.7	200	0.42	0.32	0.37	54	38	47
20	1000	1.9	1.6	1.8	200	0.50	0.42	0.48	75	54	62
20	1500	3.1	3.6	4.1	200	0.55	0.64	0.72	104	85	93
20	2000	4.5	7	7.8	200	0.60	0.93	1.03	146	124	132
20	2500	6.4	9.9	11.6	200	0.68	1.05	1.23	173	141	159
20	3000	8.2	14.1	15.9	200	0.72	1.25	1.40	204	166	187
40	500	2.4	1.8	2.1	200	1.27	0.95	1.11	83	62	74
40	1000	7.5	6.3	6.8	200	1.99	1.67	1.80	132	111	121
40	1500	17.2	14.4	15.7	200	3.04	2.54	2.77	197	167	185
40	2000	33.1	26.9	29.1	200	4.39	3.57	3.86	286	232	256
40	2500	53.9	46.8	48.9	200	5.72	4.96	5.19	374	330	342
40	3000	78	70.4	72.6	200	6.89	6.22	6.42	454	408	421
60	500	5.4	4.1	4.9	200	2.86	2.17	2.60	127	101	119
60	1000	13.9	11.1	12.7	200	3.68	2.94	3.37	161	130	147
60	1500	32.2	25	27.3	200	5.69	4.42	4.82	249	194	210
60	2000	52.2	43.3	48.4	200	6.92	5.74	6.42	302	252	281
60	2500	85.5	74.5	82.1	200	9.07	7.90	8.71	398	344	376
60	3000	123.6	113.4	118.7	200	10.92	10.02	10.49	476	432	455

Load (N)	Sliding Distance (m)	Mass loss method							System generated
		Mass loss Δm (m1-m2) (mg)			Speed (RPM)	Wear rate W_r (10^-5 mm³/m)			Wear (µm)
		A (as-cast)	A (aged at 100°C)	A (aged at 200°C)	Speed (RPM)	A (as-cast)	A (aged at 100°C)	A (aged at 200°C)	A (as-cast)	A (aged at 100°C)	A (aged at 200°C)
20	500	0.7	0.5	0.6	200	0.38	0.27	0.32	45	32	36
20	1000	1.7	1.1	1.2	200	0.46	0.30	0.32	58	38	41
20	1500	3.3	2.3	2.8	200	0.59	0.41	0.50	76	54	66
20	2000	6.4	5.1	5.8	200	0.86	0.68	0.78	111	86	102
20	2500	9.1	7.3	8.7	200	0.98	0.78	0.93	128	102	121
20	3000	12.5	9.6	11.9	200	1.12	0.86	1.07	145	110	138
40	500	1.9	1.2	1.5	200	1.02	0.64	0.81	64	42	54
40	1000	4.9	3.5	4.3	200	1.32	0.94	1.15	85	61	75
40	1500	10.6	6.9	8.2	200	1.90	1.24	1.47	123	80	98
40	2000	19.9	12.8	16.4	200	2.67	1.72	2.20	174	110	144
40	2500	36.7	22.5	30.2	200	3.94	2.42	3.24	255	157	210
40	3000	53.2	31.7	45.8	200	4.76	2.84	4.10	310	184	265
60	500	3.7	2.2	2.8	200	1.99	1.18	1.50	86	51	65
60	1000	13	6.4	8.8	200	3.49	1.72	2.36	152	76	102
60	1500	26.8	15.6	20.6	200	4.80	2.79	3.69	207	121	162
60	2000	43.5	26.4	35.5	200	5.84	3.55	4.77	252	154	206
60	2500	67.4	38.3	52.7	200	7.24	4.11	5.66	313	180	244
60	3000	91.8	53.7	73.8	200	8.22	4.81	6.61	354	208	286

Load (N)	Sliding Distance (m)	Mass loss method							System generated
		Mass loss Δm (m1-m2) (mg)			Speed (RPM)	Wear rate W_r (10^-5 mm³/m)			Wear (µm)
		A (as-cast)	A (aged at 100°C)	A (aged at 200°C)	Speed (RPM)	A (as-cast)	A (aged at 100°C)	A (aged at 200°C)	A (as-cast)	A (aged at 100°C)	A (aged at 200°C)
20	500	0.5	0.3	0.4	200	0.27	0.16	0.22	38	22	29
20	1000	1.3	0.9	1	200	0.35	0.24	0.27	47	32	37
20	1500	2.2	1.8	2.1	200	0.39	0.32	0.38	55	43	50
20	2000	4.1	3.2	3.5	200	0.55	0.43	0.47	74	57	63
20	2500	7.1	5.8	6.4	200	0.76	0.62	0.69	99	82	89
20	3000	9.3	8.3	8.6	200	0.83	0.74	0.77	109	94	100
40	500	1.7	0.6	1.4	200	0.91	0.32	0.75	58	31	49
40	1000	4.1	3.2	3.6	200	1.10	0.86	0.97	71	56	63
40	1500	9.9	6.3	7.6	200	1.78	1.13	1.36	116	74	92
40	2000	18.1	11.5	15.1	200	2.43	1.55	2.03	158	102	130
40	2500	32.2	19.2	24.1	200	3.46	2.07	2.59	224	135	169
40	3000	49.2	28.5	41.3	200	4.41	2.56	3.70	287	166	241
60	500	3.1	0.9	2.1	200	1.67	0.48	1.13	72	22	51
60	1000	11.2	4.6	7.5	200	3.01	1.24	2.02	131	52	86
60	1500	24.3	11.9	18.9	200	4.36	2.13	3.39	189	96	147
60	2000	38.6	20.8	32.3	200	5.19	2.80	4.34	226	121	188
60	2500	62.9	32.8	45.8	200	6.77	3.53	4.93	293	152	213
60	3000	78.6	48.5	59.5	200	7.05	4.35	5.33	305	188	229

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[1] *e-mail: ss.sharma@manipal.edu