BCA

Experimental Investigation of Tribological Properties of ZA43 Hybrid Composite
CHAPTER 1
INTRODUCTION
1.1 Composites
A composite is a structural material that consists of two or more combined constituents

that are combined at a macroscopic level and are not soluble in each other. One constituent is
called the reinforcing phase and the other in which it is embedded is called the matrix. The
reinforcing phase material may be in the form of fibers, particulates, or flakes. The matrix
phase materials are generally continuous.
The primary functions of the matrix are to transfer stresses between the reinforcing
fibers/particles and to protect them from mechanical and/or environmental damage whereas the
presence of fibers/particles in a composite improves its mechanical properties such as strength,
stiffness etc. A composite is therefore a synergistic combination of two or more micro-
constituents that differ in physical form and chemical composition and which are insoluble in
each other. The objective is to take advantage of the superior properties of both materials
without compromising on the weakness of either.
Composite materials have successfully substituted the traditional materials in several light
weight and high strength applications. The reasons why composites are selected for such
applications are mainly their high strength-to-weight ratio, high tensile strength at elevated
temperatures, high creep resistance and high toughness. Typically, in a composite, the
reinforcing materials are strong with low densities while the matrix is usually a ductile or
tough material. If the composite is designed and fabricated correctly it combines the strength of
the reinforcement with the toughness of the matrix to achieve a combination of desirable
properties not available in any single conventional material. The strength of the composites
depends primarily on the amount, arrangement and type of reinforcement in the resin.
Department of Mechanical Engineering, BIET Davangere Page 1

1.2 Metal Matrix Composites

Metal matrix composites (MMCs), as the name implies, have a metal matrix. Examples
of matrices in such composites include aluminum, magnesium and titanium. Typical fibers
include carbon and silicon carbide. Metals are mainly reinforced to increase or decrease their
properties to suit the needs of design. For example, the elastic stiffness and strength of metals
can be increased and large coefficients of thermal expansion and thermal and electric
conductivities of metals can be reduced, by the addition of fibers such as silicon carbide,
graphite.
Metal Matrix Composites (MMCs) are a diverse class of materials that consist of a
metallic alloy matrix typically reinforced with a ceramic phase in the form of particulates,
platelets, whiskers, short fibers, and continuously aligned fibers. Metal matrix composites
(MMCs) are used in structural applications, and in applications requiring wear resistance,
thermal management, and weight savings. By far the most common commercial MMCs are
based on aluminum, magnesium, and titanium alloys reinforced with silicon carbide (Sic),
alumina (Al2O3), carbon, or graphite.
The reinforcement material is embedded into the matrix. The reinforcement does not
always serve a purely structural task (reinforcing the compound), but is also used to change
physical properties such as wear resistance, friction coefficient, or thermal conductivity. The
incorporation of the reinforcement increases the stiffness and strength of the matrix. However,
the improvements in stiffness and strength generally come at the expense of ductility and
fracture resistance.
The reinforcement can be either continuous or discontinuous. Discontinuous MMCs

can be isotropic, and can be worked with standard metalworking techniques, such as extrusion,
forging or rolling. In addition, they may be machined using conventional techniques.
Continuous reinforcement uses mono-filament wires or fibers such as carbon fiber or silicon
carbide. Because the fibers are embedded into the matrix in a certain direction, the result is an
anisotropic structure in which the alignment of the material affects its strength. One of the first
MMCs used boron filament as reinforcement.
Typically, ceramics and graphitic materials are used as reinforcement phases in

discontinuously reinforced MMCs. Discontinuous reinforcement uses "whiskers", short fibers,
or particles. The most common reinforcing materials in this category are alumina and silicon
carbide
Discontinuously reinforced MMCs are much less expensive to fabricate than
continuously reinforced composites. Consequently, performance enhancement of the matrix
comes at lower additional costs with discontinuous reinforcements compared with aligned
reinforcements. Furthermore, the properties of discontinuously reinforced composites are
nearly isotropic, whereas the properties of composites with continuous aligned reinforcements
are highly anisotropic. Thus, in applications requiring isotropic properties, less expensive,
discontinuously reinforced composites can outperform continuous fiber reinforced composites.
1.2.1 Particulate Reinforced Metal Matrix Composite
Particulate reinforced metal matrix composites have been used extensively in various fields
due to their cost-effectiveness, high interfacial bonding and easy to form into complex shapes.
Besides, they behave isotropically and are not as sensitive as long fiber composites to the
mismatch of thermal expansion between the matrix and the reinforcement. Generally
particulate fillers are used in metal matrix for a variety of reasons such as cost reduction,
improved processing, density control, and thermal conductivity, control of thermal expansion,
electrical properties, magnetic properties, improved hardness and better wear resistance.

1.3 GENERAL PROPERTIES OF MMC’s

The metal matrix composites have various advantages over other types of composites. Such
as;
 High strength
 High modulus
 High toughness and impact properties
 Low sensitivity to changes in temperature or thermal shock
 High surface durability and low sensitivity to surface flaws
 High electrical conductivity
 Excellent reproducibility of properties
 Excellent technological background with respect to
 Design
 Manufacture
 Shaping and forming
 Joining and finishing
 Service durability information
The high strength values of metal alloys, compared to structural ceramics or organic materials,
which can be utilized in composite materials, make them attractive. This high strength is
mostly important with respect to composite properties at a direction different from the
reinforcement direction. Properties such as transverse strength, tensional strength and
interlaminar shear strength are examples of matrix strength controlled properties.
The high module of metal alloys compared to those of organic materials is particularly
significant in high modulus composites. The high toughness and impact properties of metal
alloys are very important, since the reinforcement is generally a linear elastic material and does
not have good impact properties. Ductile metal matrix alloys such as aluminum, titanium or
nickel-chromium alloys undergo energy-absorbing plastic deformation under impact, which is
a desirable property for dynamic applications. The ductile metal matrix gives also improved
fracture toughness.

The comparably low thermal sensitivity of metal matrices enhances their uses in high-modulus
structural composites. Other organic matrix materials are quite sensitive to temperature
changes. They are more resistant to thermal shocks the than ceramic matrices are. At elevated
temperatures, not only do they tend to soften but also their resistance to oxidation, corrosion
and erosion drops off significantly.
The metal matrices are generally less sensitive to surface flaws than ceramics or organic resins
so their surfaces are more durable. The organic resins are more sensitive to small cracks
because of various reasons such as low hardness and strength, moisture sensitivity, tendency of
porosity, sensitivity to moderate temperature oxidation and ultraviolet radiation.
Another advantage of metal matrix alloys is their high thermal and electrical conductivity,
which permits the diffusion and elimination of high thermal and electrical concentrations.
Problems such as lightning strikes and hot-gas impingement are less severs if the impacting
energy can be conducted away more rapidly.
Another important asset of metal matrices is their excellent reproducibility of their metal
properties. This property is important not only for matrix alloy properties but also the bonding
and the interfacial properties.
Another important advantage of metal matrix alloys is the availability of an excellent

technological background of their present use in the design of engineering structures,
manufacturing techniques and a comprehensive information on service durability.
Although metal matrix composites have a lot of advantages, they have some important
disadvantages. One of the most important disadvantages is that the metal matrices are poor in
chemical and mechanical compatibility with the reinforcements. In other words, the chemical
inertness of the reinforcement (usually a fiber) at modest resin-fabrication temperatures and
large elastic compliance of the matrix are the chemical and mechanical incompatibility
problems.

1.4 APPLICATION OF MMC’s
 Aerospace
 Automobile
 Pressure vessel and pipes
 Power conduction
 Wear resistant materials
 Filamentary supper conducting magnets
1.5 ADVANTAGES OF MMCs
 Increased specific strength

 Increased specific stiffness
 Increased elevated temperature strength
 Improved wear resistance
 Lower density
 Improved dumping capabilities
 Tolerable thermal expansion coefficients
 Good corrosion resistance
1.6 LIMITATION OF MMCs
 Composite are heterogeneous

 Composite are highly anisotropic
 Composite materials are difficult to inspect with conventional ultrasonic, eddy current
and visual NDI methods such as radiography.
 Repair can be difficult

CHAPTER 2
LITERATURE REVIEW
This chapter covers the literature review of results obtained from investigations on the dry
sliding wear and abrasive wear behavior of Aluminium Metal Matrix Composites (AMMCs).
Many research works have done on the processing of aluminium- Sic Composite, wear
characteristics evaluation and Stir Casting, which have influenced this project.
2.1 Literature Review

Manoj Singla, D. Deepak Dwivedi, Lakhvir Singh, Vikas Chawla made the modest
attempt to develop aluminium based silicon carbide particulate MMCs with an objective to
develop a conventional low cost method of producing MMCs and to obtain homogenous
dispersion of ceramic material. To achieve these objectives two step-mixing method of stir
casting technique has been adopted and subsequent property analysis has been made.
Pardeep Sharma,Gulshan Chauhan and Neeraj Sharma “Production of AMC by Stir

Casting”. They studied various process of stir casting for production of Aluminum-matrix
composite and parameter of stir casting and difficulties encountered in successful
manufacturing of AMC by stir casting (ISSN:2231-5608).
Yilmaz (2007) studied the effects of volume fraction and size of SiCrFe, CrFeC, and Al2O3
particulates on the abrasive wear rate of compo casted Al 2024 metal matrix composites. The
lowest wear rate was obtained for composites having CrFeC, SiCrFe and Al2O3 particulates
together. This low wear rate was attributed to the chemical bond between intermetallic and
matrix as well as due to uniform distribution of the particulates in the matrix.
Acilar and Gul (2004) investigate that both the 10%, 30% Sic particle reinforced with Al-10Si
composites found that the wear rate of composites increased with increasing sliding distance
and applied load. The damage to the surface of the composites increased with increasing load

since matrix materials did not have enough resistance and therefore volumetric wear rate of the
composites were higher.
G. B. Veeresh Kumar, C. S. P. Rao, N. Selvaraj, M. S. Bhagyashekar investigated the

mechanical and tribological properties of ZnAl-SiC and Metal Matrix Composites. From their
experiment they found that the dispersed SiC& Al2O3 in ZnAl alloy contributed in enhancing
the tensile strength of the composites. The tensile strength properties of the composites are
found higher than that of base matrix ZnAl. The wear resistance of the composites are higher,
further the SiC contributed significantly in improving wear resistance of ZnAl composites.
Basavarajappa et al. (2007) observed that the wear rate for Al2219/15 wt.% SiC composites
and Al2219/15 wt.% SiC/3%Gr hybrid composites were almost unchanged with an increase in
sliding speed up to 3 m/s. Beyond 3 m/s, the wear rate of the unreinforced alloy increased to
larger values than those of the composites and seizure was observed at a sliding speed of 6.1
m/s. At a sliding speed of 6.1 m/s, wear by delamination was observed to occur in the alloy
with fragments from the pin being transferred to the disc as well as to larger fragments.
However, the wear rates of the composites almost unchanged with increase in sliding speed up
to 4.6 m/s after which there was increasing in wear rate.
N. Radhika, R. Subramanian, S. Venkat Prasad investigated Tribological behaviour of

aluminium alloy (Al-Si10Mg) reinforced with alumina (9%) and graphite (3%) fabricated by
stir casting process. The wear and frictional properties of the hybrid metal matrix composites
was studied by performing dry sliding wear test using a pin-on-disc wear tester. Experiments
were conducted based on the plan of experiments generated through Taguchi‟s technique. A
L27 Orthogonal array was selected for analysis of the data. Investigation to find the influence
of applied load, sliding speed and sliding distance on wear rate, as well as the coefficient of
friction during wearing process was carried out using ANOVA and regression equations for
each response were developed. Results show that sliding distance has the highest influence
followed by load and sliding speed. Finally, confirmation tests were carried out to verify the
experimental results and Scanning Electron Microscopic studies were done on the wear
surfaces.

2.2 Objective of the Present Work
The potential for developing high performance SiC reinforced Aluminium based matrix
composites using ZA43 alloy as a matrix has formed the thrust of this work.
The objective of the Present Work is to study the wear behavior of ZA43 metal matrix
composite (MMC) with addition of varying percentage composition of SiC and Al2O3 particles
made by stir casting techniques. The wear and frictional properties of the metal matrix
composites was studied by performing dry sliding wear test using a pin-on-disc wear tester.
The objectives of the present work are as follows:
 To prepare the cost-effective MMC material by taking ZA43 as matrix and

Silicon carbide and aluminium oxide as reinforced phase using stir casting
technique.
 To investigate the Density, Wear Rate and Coefficient of Friction for different
volume fraction of silicon carbide and Aluminium oxide reinforced ZA43 Metal
Matrix Composites.
 To determine wear and frictional properties of the metal matrix composites
using dry sliding wear test on a computerized pin-on-disc wear tester for
varying
 To choose the material composition having better tribological properties from
the experimental result.

CHAPTER 3
WEAR
3.1 Introduction
Wear is defined as the damage to a solid surface usually involving progressive loss of
materials, owing to relative motion between the surface and a contacting substance or
substances. It is a material response to the external stimulus and can be mechanical or chemical
in nature.
The effect of wear on the reliability of industrial components is recognized widely and the cost of
wear has also been recognized to be very high. Systematic efforts in wear research were started in
1960s in industrialized countries. The direct costs of wear failures (i.e. wear part replacements),
increased work and time, loss of productivity as well as indirect losses of energy and the increased
environmental burden are real problems in everyday work and business. In catastrophic failures,
there is also the possibility of human losses. Although wear has been extensively studied
scientifically, still wear problems persist in industrial applications. This actually reveals the
complexity of the wear phenomenon.
One third of our global energy consumption is consumed wastefully in friction. In addition to
this primary saving of energy, very significant additional economics can be made by the
reduction of the cost involved in the manufacture and replacement of prematurely worn out
components. The dissipation of energy by wear impairs strongly the national economy and the
life style of most of people. So, the effective decrease and control of wear of metals is always
desired. Wear causes an enormous annual expenditure by industry and consumers. Most of this
is replacing or repairing equipment that has worn to the extent that it no longer performs a
useful function. For many machine components this occurs after a very small percentage of the
total volume has been worn away. For some industries, such as agriculture, as many as 40% of
the components replaced on equipment have failed by abrasive wear. Other major sources of
expenditure are losses production consequential upon lower efficiency and plant shutdown, the
need to invest more frequently in capital equipment and increased energy consumption as

equipment wears. Estimates of direct cost of abrasive wear to industrial nations vary from 1 to
4 % of gross national product.
3.2 Classification of Wear
Wear occurs as a natural consequence when two surfaces with a relative motion interact with
each other. Wear may be defined as the progressive loss of material from contacting surfaces
in relative motion. Scientists have developed various wear theories in which the Physico-
Mechanical characteristics of the materials and the physical conditions.
In most basic wear studies where the problems of wear have been a primary concern, the so-
called dry friction has been investigated to avoid the influences of fluid lubricants.
Dry friction is defined as friction under not intentionally lubricated conditions but it is well
known that it is friction under lubrication by atmospheric gases, especially by oxygen.
Types of wear are:
(1) Abrasive
(2) Adhesive
(3) Erosive
(4) Surface fatigue
(5) Corrosive.
3.2.1 Abrasive wear
Abrasive wear can be defined as wear that occurs when a hard surface slides against
and cuts groove from a softer surface. It can be account for most failures in practice. Hard
particles or asperities that cut or groove one of the rubbing surfaces produce abrasive wear.
This hard material may be originated from one of the two rubbing surfaces.
In sliding mechanisms, abrasion can arise from the existing asperities on one surface (if it is
harder than the other), from the generation of wear fragments which are repeatedly deformed

and hence get work hardened for oxidized until they became harder than either or both of the
sliding surfaces, or from the adventitious entry of hard particles, such as dirt from outside the
system.
Two body abrasive wear occurs when one surface (usually harder than the second)
cuts material away from the second, although this mechanism very often changes to three body
abrasion as the wear debris then acts as an abrasive between the two surfaces.
Abrasives can act as in grinding where the abrasive is fixed relative to one surface or
as in lapping where the abrasive tumbles producing a series of indentations as opposed to a
scratch. According to the recent tribological survey, abrasive wear is responsible for the largest
amount of material loss in industrial practice.
3.2.2Adhesive wear
Adhesive wear can be defined as wear due to localized bonding between contacting solid
surfaces leading to material transfer between the two surfaces or the loss from either surface.
For adhesive wear to occur it is necessary for the surfaces to be in intimate contact with each
other. Surfaces, which are held apart by lubricating films, oxide films etc. reduce the tendency
for adhesion to occur.

3.2.3 Erosive wear

Erosive wear can be defined as the process of metal removal due to impingement of solid
particles on a surface. Erosion is caused by a gas or a liquid, which may or may not carry,
entrained solid particles, impinging on a surface. When the angle of impingement is small, the
wear produced is closely analogous to abrasion. When the angle of impingement is normal to
the surface, material is displaced by plastic flow or is dislodged by brittle failure.
3.2.4 Surface fatigue wear

Wear of a solid surface caused by fracture arising from material fatigue. The
term“fatigue” is broadly applied to the failure phenomenon where a solid is subjected to cyclic
loading involving tension and compression above a certain critical stress. Repeated loading
causes the generation of micro cracks, usually below the surface, at the site of a pre-existing
point of weakness. On subsequent loading and unloading, the micro crack propagates. Once the
crack reaches the critical size, it changes its direction to emerge at the surface, and thus flat
sheet like particles is detached during wearing. The number of stress cycles required to cause
such failure decreases as the corresponding magnitude of stress increases. Vibration is a
common cause of fatigue wear.

3.2.5 Corrosive wear

Most metals are thermodynamically unstable in air and react with oxygen to form an oxide,
which usually develop layer or scales on the surface of metal or alloys when their interfacial
bonds are poor. Corrosion wear is the gradual eating away or deterioration of unprotected
metal surfaces by the effects of the atmosphere, acids, gases, alkalis, etc. This type of wear
creates pits and perforations and may eventually dissolve metal parts.
3.3 Symptoms of Wear

A summary of the appearance and symptoms of different wear mechanism is indicated in Table
3.3

CHAPTER 4
MATERIAL SELECTION
In our project we have used four materials combinations such as Aluminium and Zinc as
major matrix components and aluminium oxide & silican carbide as subtituent components.
The purpose of using aluminium oxide & silicon carbide is that it gives strength, toughness and
reduces wear rate as we vary the percentage compositions.
The following individual properties of each component are given below.
4.1 ALUMINIUM
 It is easily formed, machined and can be casted.
 It is light metal, non toxic, non magnetic, and non sparking.
 The metal is malleable and easily worked by manufacturing and shaping processes.
 It has low density, low strength and high ductility.
 It posses high reflectivity and heat conduction properties.
 Young’s modulus: 68.242GPa.
 Density: 2700Kg/m3.
 Thermal conductivity: 237W/m/K.
 Melting point:933K

Fig 4.1: Aluminium ingots
4.2 ZINC
 The metal is hard and brittle at most temperature but becomes malleable between 100c
and 150c.
 It has low melting (692K) point.
 It’s a good conductor of electricity.
 It has a good corrosion resistance property.
Fig 4.2: Zinc metal

4.3 ZA43
 The main constituents of Zinc-Aluminium alloys are Zinc and Aluminium with other
elements like magnesium and copper.
 Aluminium which is in higher percentage responsible for increase in hardness of base

alloy.
 ZA43 is mixed with Al2O3 and Sic to make a hybrid composite to impart more
corrosion resistance, fatigue resistance.
 ZA43 has not only a good density but also good physical, mechanical, processing
properties.
 The alloy is suitable for making good wear resistant parts like bush, axle sleeve, worm
wheel etc.
 Composition of ZA43 alloy (wt. %) is given.
Element Percentage
Al 43
Cu 2.5
Mg 0.02
Fe 0.012
Zn balance

4.4 SILICON CARBIDE
Silicon carbide is composed of tetrahedral of carbon and silicon atoms with strong bonds in the
crystal lattice. This produces a very hard and strong material. Silicon carbide is not attacked by
any acids or alkalis or molten salts up to 800°C. In air, Sic forms a protective silicon oxide
coating at 1200°C and is able to be used up to 1600°C. The high thermal conductivity coupled
with low thermal expansion and high strength gives this material exceptional thermal shock
resistant qualities. Some typical uses of silicon carbide are found in fixed and moving turbine
components, seals, bearings, heat exchangers etc.
Key Properties
 Low density
 High strength
 Low thermal expansion
 High hardness
 High elastic modulus
 Excellent thermal shock resistance

Fig 4.3 Silicon Carbide
4.5 ALUMINIUM OXIDE
Aluminum oxide, commonly referred to as alumina, possesses strong ionic inter atomic
bonding giving rise to it’s desirable material characteristics.
 Hard, wear-resistant
 Resists strong acid and alkali attack at elevated temperatures
 Good thermal conductivity
 Excellent size and shape capability
 High strength and stiffness.
 Available in purity ranges from 94%, an easily metallizable composition,

to 99.8% for the most demanding high temperature application

Fig 4.4: Aluminium oxide

CHAPTER 5
CASTING
Among the variety of manufacturing processes available for discontinuous metal

matrix composites, stir casting is generally accepted as a particularly promising route,
currently practiced commercially. Its advantages lie in its simplicity, flexibility and
applicability to large quantity production. It is also attractive because, in principle, it
allows a conventional metal processing route to be used, and hence minimizes the final
cost of the product. This liquid metallurgy technique is the most economical of all the
Available routes for metal matrix composite production, and allows very large sized
components to be fabricated.
5.1 Stir Casting: Procedure

Stir Casting is a liquid state method of composite materials fabrication, in which a
dispersed phase (ceramic particles, short fibers) is mixed with a molten matrix metal by
means of mechanical stirring. The liquid composite material is then cast by
conventional casting methods and may also be processed by conventional Metal
forming technologies. The Al sheets cut into pieces were melted in the furnace as
shown in fig. After melting Al melt was super-heated to desired temperature.
Fig 5.1: stir casting

0
The Sic reinforcement particles are preheated to around 500 C. The preheating is carried out to
increase the wettability of the reinforcement. The permanent die is made up of mild steel also kept
for pre heating to remove the moisture, improve the solidification. To eliminate blow holes in the
specimen and to get sound casting degasifier tablets are used .This tablets allow the gases to escape
which are trapped in the molten metal.
Then the required amounts of Sic & Al2O3 were added to the Al melts while stirring
with stirrer coated with ceramic at a suitable speed (500 rpm) for a duration of 8 to 10 minutes.
The molten Al-Sic alloys were poured into a split type permanent mold & it was allowed for
solidification. The Al-Sic alloy bars were taken out from the mold. After solidification, the
castings are taken from the mold and are cut to the required shape and sizes for wear test.
Fig 5.2: Mold

5.2 MACHINING
Fig 5.3: Machining Process

CHAPTER 6
EXPERIMENTATION
6.1 Pin-on-Disc Wear Testing Machine
Experiments have been conducted in the Pin-on-disc type Friction and Wear monitor
(DUCOM; TL-20) with data acquisition system, (Fig. 6.1) which was used to evaluate the wear
behavior of the composite, against hardened ground steel disc (En-32) having hardness 65
HRC and surface roughness (Ra) 0.5 μm. It is versatile equipment designed to study wear
under sliding condition only. Sliding generally occurs between a stationary Pin and a rotating
disc. The disc rotates with the help of a D.C. motor; having speed range 0-2000 rev/min with
wear track diameter 80 mm-180 mm, which could yield sliding speed 0 to 10 m/sec. Load is to
be applied on pin (specimen) by dead weight through pulley string arrangement. The system
has a maximum loading capacity of 200N.
Fig 6.1: Pin on disc machine

A LVDT (load cell) on the lever arm helps determine the wear at any point of time by
monitoring the movement of the arm. Once the surface in contact wears out, the load pushes
the arm to remain in contact with the disc. This movement of the arm generates a signal which
is used to determine the maximum wear and the coefficient of friction is monitored
continuously as wear occurs and graphs between coefficient of friction and time was
monitored for the each specimens. Further, weight loss of each specimen was obtained by
weighing the specimen before and after the experiment by a single pan electronic weighing
machine with an accuracy of 0.0001g after thorough cleaning with acetone solution.
6.2 Test Parameters

The amount of wear in any system will, in general, depend upon the number of system factors
such as the applied load, machine characteristics, sliding speed, sliding distance, the
environment, and the material properties. The value of any wear test method lies in predicting
the relative ranking of material combinations.
The test parameters in a Pin on Disc machine are as follows:
1. Load: Values of the force in Newton at the wearing contact.
2. Speed: The relative sliding speed between the contacting surfaces in meters per second.
3. Distance: The accumulated sliding distance in meters.
4. Temperature: The temperature of one or both specimens at locations close to the wearing
contact.

6.3 Procedure
1. Immediately prior to testing, and prior to measuring or weighing, clean and dry the
specimens. Take care to remove all dirt and foreign matter from the specimens. Use no
chlorinated, non-film-forming cleaning agents and solvents.
2. Measure appropriate specimen dimensions to the nearest 2.5 μm or weigh the

Specimens to the nearest 0.0001 g.
3. Insert the disk securely in the holding device so that the disk is fixed perpendicular to the
axis of the resolution.
4. Insert the pin specimen securely in its holder and, if necessary, adjust so that the specimen
is perpendicular to the disk surface when in contact, in order to maintain the necessary contact
conditions.
6. Add the proper mass to the system lever or bale to develop the selected force pressing the
pin against the disk.
7. Start the motor and adjust the speed to the desired value while holding the pin specimen out
of contact with the disk. Stop the motor. Set the revolution counter (or equivalent) to the
desired number of revolution.
8. Begin the test with the specimens in contact under load. The test is stopped when the
desired number of revolutions is achieved. Tests should not be interrupted or restarted.
9. Remove the specimens and clean off any loose wear debris.
10. Remeasure the specimen dimensions to the nearest 2.5 μm or reweigh the specimens to the
nearest 0.0001 g, as appropriate.

11. Repeat the test with additional specimens to obtain sufficient data for statistically
significant results.
6.4 METHODOLOGY
6.4.1 Taguchi method
It is a powerful tool for designing high quality system based on Orthogonal Array
(OA). Experiments that provide much reduced variance for the experiments with an optimum
set of process control parameter. It introduces an integrated approach which is simple and
efficient to find the best range of design for quality performance and computational cost. This
method archives the integration of design of experiments with the parametric optimization of
the process yielding the desired results. The traditional experiments design procedure focuses
on the average process performance characteristics. But the Taguchi method concentrates on
the effect of variation on the process quality characteristics rather than its average. That is the
Taguchi approach makes the process performance insensitive to variation in uncontrolled or
noise factors. The Taguchi recommends that this can be done by the proper design of
parameter during the “parameter design” phase off-line quality control. He designed certain
standard OA’s by which simultaneously and independent valuation of two or more parameter
for their ability to affect the variability of the particulate product or process characteristics can
be done in a minimum number of steps.
The Taguchi method uses a tactical measure of performance i.e. Analysis Of variance
(ANOVA) is performed to find which process parameters are statically significant. With the
ANOVA analysis, the optimal combination of the process parameters can be predicted.
6.4.2 Wear Behavior

The aim of the expariment is to find the imporrtent factors and combination of factors
influencing the wear rate and coefficent of friction. The experiments were develoed based on
the orthogaonal array, with the aim of relating the influences of sliding speed, applaied load

and sliding distances. These design parameters are distinct and intensic features of the process
that inflences and determine the composite performance.
The above mentioned pin on disc test appartus was used to composite. Specimens of
size 10mm diameter and 30 mm length wear cut and machined from the cast samples. The
contact surface of the cast samples was made flat so that it should be in contact with the
rotating disc. During the test the specimen was held pressed againest a rotating EN32 carbon
steel disc by applying load that acts as a counterweight and balance the pin. The track diameter
was varied for each batch of expariments in the range of 50-160mm and the parameters such as
the load, sliding speed, and sliding distances were varied in the range given Table 1. A LVDT
on the lever arm helps to determine the wear at any point of time by monitoring the moment of
the arm. Once the surface in contact wears out, the load pushes the arm to remain in contact
with the disc. Furthermore weight loss of each specimen was obtained by weigheing machine
with an accuracy of 0.0001g after through cleaning with acetone solution.
Table 1: Process Parameters
Level load(kg) Speed(m/s) Siding distance(m)

1 1 200 600
2 2 300 1200
3 3 400 1800
4 4 500 2400

6.4.3 Plan of Experiments
Dry sliding wear test was performed with the three parameter load, speed and distance
and varying them for the three levels. Accordingly to the rule that degree of freedom for the
orthogonal array should be greater than or equal to sum of those wear parameters.
Orthogonal array L16 of Taguchi
Sl No Load(Kg) Speed (rpm) Sliding distance(m) Composition (%)

1 1 1 1 1
2 1 2 2 2
3 1 3 3 3
4 1 4 4 4
5 2 1 2 3
6 2 2 3 4
7 2 3 4 1
8 2 4 1 2
9 3 1 3 4
10 3 2 4 1
11 3 3 1 2
12 3 4 2 3
13 4 1 4 1
14 4 2 1 2
15 4 3 2 3
16 4 4 3 4

CHAPTER 7
RESULT AND DISCUSSION
The experiments were conducted on “Pin on Disc” tester to analyses the dry sliding
wear behavior. The aim of experiment plan is to find the importance of the factors influence
the wear process to achieve the minimum wear rate. The experiments were developed based on
the orthogonal array, with the aim of relating influence of load, speed and distance. These
design parameter are distinct and intrinsic feature of the process that influences and determine
the composite performance. Results were analyzed using the commercial software “MINITAB
16” specially used for design of experiments.
Notations:
Specimen indication Composition
Specimen 1(A,B,C,D) ZA43
Specimen 2(A,B,C,D) ZA43+Sic(1.5)+Al2O3(1.5)
Specimen 3(A,B,C,D) ZA43+Sic(1)+Al2O3(2)
Speciman4(A,B,C,D) ZA43+Sic(2)+Al2O3(1)
7.1 Result by using single parameter at a time approach

Table 7.1a: experiment conducted keeping SPEED constant
Composition Parameter Initial wt-Final wt

Speed Load(kg) Time(min) gms
1A 300 1 5 0.0089
1B 300 2 5 0.0224
1C 300 3 5 0.0436
1D 300 4 5 0.1366
2A 300 1 5 0.0047

2B 300 2 5 0.0084
2C 300 3 5 0.0096
2D 300 4 5 0.0091
3A 300 1 5 0.0206
3B 300 2 5 0.0098
3C 300 3 5 0.0173
3D 300 4 5 0.02887
4A 300 1 5 0.0116
4B 300 2 5 0.0055
4C 300 3 5 0.0111
4D 300 4 5 0.0202
Table7.1b: Experiment conducted keeping LOAD constant

1A 100 2 5 0.0192
1B 200 2 5 0.0158
1C 300 2 5 0.0057
1D 400 2 5 0.0307
2A 100 2 5 0.0024
2B 200 2 5 0.0034
2C 300 2 5 0.0097
2D 400 2 5 0.0124
3A 100 2 5 0.0016

3B 200 2 5 0.0064
3C 300 2 5 0.0077
3D 400 2 5 0.0097
4A 100 2 5 0.0011
4B 200 2 5 0.0038
4C 300 2 5 0.0058
4D 400 2 5 0.0117
Table 7.1c: Experiment conducted for SLIDING DISTANCE.

1A 200 3 2.43 0.0026
1B 200 3 5.27 0.0076
1C 200 3 8.11 0.0132
2A 200 3 2.43 0.0027

2B 200 3 5.27 0.0053
2C 200 3 8.11 0.0104
3A 200 3 2.43 0.002

3B 200 3 5.27 0.0051
3C 200 3 8.11 0.0124
4A 200 3 2.43 0.0028

4B 200 3 5.27 0.009
4C 200 3 8.11 0.009

7.2 Graphs for single parameter approach
Wear rate Vs Load

100
90
80
70
1
60
Wear rate
2
50
3
40
4
30
20
10
0
1 2 Load 3 4
Fig 7.1: Wear rate v/s load when speed is constant
Wear rate Vs Speed

120
100
80 1
Wear rate
2
60
3
4
40
20
0
100 200 300 400
Speed
Fig 7.2: Wear rate v/s speed when load is constant

Wear rate Vs Sliding distance

60
50
40
1
Wear rate
2
30
3
4
20
10
0
600 1200 1800
Sliding distance
Fig 7.3: Wear rate v/s sliding distance when speed and load is constant
Notations:
Curve indication Composition
1 ZA43
2 ZA43+Sic(1.5)+Al2O3(1.5)
3 ZA43+Sic(1)+Al2O3(2)
4 ZA43+Sic(2)+Al2O3(1)
It can be observed that, wear rate increases with decrease in percentage of silicon
carbide and aluminium oxide particles in the composites. But with increase in
load, speed and sliding distance the wear rate tends to increase, indicating that
with higher speed, higher load, higher sliding distance and with lower percentage
of Sic and aluminium oxide wear rate increase as compared to the lower speed,
load, sliding distance and with higher percentage.

7.2 Taguchi method
The plan of test developed with the aim of relating the influence of load, speed and
distance on the dry sliding wear behavior of composite. On conducting the experiments as per
L9 orthogonal array, the wear test for various combination of parameter were obtained as
shown in Table.
7.2.1 Orthogonal array L16 of Taguchi
Load(kg) speed(rpm) Sliding Composition Wt loss

distance(mm) gms
1 200 600 0.0 0.3540
1 300 1200 1.0 0.0027
1 400 1800 1.5 0.0012
1 500 2400 2.0 0.0046
2 200 1200 1.5 0.0100
2 300 600 2.0 0.0111
2 400 2400 0.0 0.0092
2 500 1800 1.0 0.0025
3 200 1800 2.0 0.0151
3 300 2400 1.5 0.0477
3 400 600 1.0 0.0026
3 500 1200 0.0 0.0122
4 200 2400 1.0 0.0400
4 300 1800 0.0 0.0032
4 400 1200 2.0 0.0139
4 600 600 1.5 0.0670

7.2.2 Analysis of variance (ANOVA)
The experiment results were analyzed with the help of ANOVA which is used to
investigate the influence of the considered wear parameters namely. Load, Sliding Speed, and
Sliding Distance that significantly affect the performance measures
By performing ANOVA, it can be decided which is independent factor dominates over

the other and the percentage of contribution of that particular independent variable. This
analysis is carried out for a significant level 0.05 that is for a confidence level of sources with
a p-value less than 0.05 were considered to have a statistical contribution to the performance
measures.
7.2.3 ANOVA results

Source DF Seq SS Adj SS Adj MS F % of
contribution
Load 3 0.0012611 0.0012611 0.0004204 1.28 26.66
Speed 3 0.0007712 0.0007712 0.0002571 0.78 16.25
Distance 3 0.0015976 0.0015976 0.0005325 1.63 33.95
Composition 3 0.0010910 0.0010910 0.0003637 1.11 23.12
Error 3 0.0009825 0.0009825 0.0003275
Total 15 0.0057035 5.7E-3 1.9012E-3 4.8 99.98
DF = Distance Factor
Seq SS =Sequential sum square
AdjSS =Adjacent sum square
AdjMS = Adjacent mean square
F= Fraction

7.2.4 Main Effects plot for weight loss
Main Effects Plot for weight loss

Data Means
A B
0.100
0.075
0.050
0.025
0.000
Mean
1 2 3 4 200 300 400 500

C D
0.100
0.075
0.050
0.025
0.000
600 1200 1800 2400 0.0 1.0 1.5 2.0
A =Load(kg)
B=Speed(rpm)
C=Sliding distance(mm)
D=Percentage of combination(%)

By using DOE Taguchi experimental orthogonal L16 array:
(Theoretical result):
The wear rate is dominated by different parameters in the order of applied load, speed,
sliding distance and percentage combinations. The optimal parameter combination
obtained by above graph for 2kg load,400rpm speed,1800mm sliding distance and
4th combination(Sic 2% Al2o3 1%) was found that wear rate was minimum when
compared to remaining combinations.
(Experimental result):
LOAD SPEED SLIDING FINALWT- AVERAGE

DISTANCE INITIAL WT gms
2 Kg 400 rpm 1800mm 0.0010
gms 0.0011
2Kg 400rmp 1800mm 0.0012
gms
Hence on comparing we found that the result obtained for both theoretical and
experimental was nearly same.
As the weight loss is low for this composition, it indicates that wear rate is also low, hence
it can be used as various applications where the wear rate required is minimum.

CHAPTER 8
CONCLUSION
The Taguchi’s robust design method can be used to analyze the drive sliding wear problem of
the matrix composites. The following conclusions can be drawn from the work.
1. The optimal wear rate was obtained from the experiment using Taguchi’s method.
2. The incorporation of Sic particles in metal matrix as secondary reinforcement
increases wear resistance of materials.
3. 1. Aluminum based metal matrix composites have been successfully fabricated by stir
casting technique with fairly uniform distribution of Silicon carbide particles.
4. The densities of the composites are found improved than their base matrix.
5. It is found that wear rate tends to decrease with increasing particles volume percentage
of silicon carbide (0-1-1.5-2%), which confirms that Sic is beneficial for reducing the
wear rate of MMCs.
6. Design of experiments approach by Taguchi’s method enables us to analyze
successfully wear behavior of the composites with filler materials, load, sliding
distance, speed and percentage of composition as the test variables.
7. The wear rate is dominated by different parameters in the order of applied load, speed,
sliding distance and percentage combinations. The ANOVA test concluded that for 2kg
load,400rpm speed,1800mm sliding distance and 4th combination(Sic 2%) was
found that wear rate was minimum when compared to remaining combinations.

8.1 Scope for future work:
1.Same metal matrix composites can be manufactured by using other manufacturing techniques

like spray casting, powder metallurgy etc. and results can be compared

with stir casting technique.
2.Same metal matrix composites can be manufactured with different percentage of reinforced

SiC and aluminium oxide with ZA43 matrix composite.

materials making it Hybrid composites and results can be compared with present work.
3.Heat treatment of the MMCs at different temperature range and quenching media like water,

oil and brine solution etc. can be used to achieve better results.
COST OF ESTIMATION:
Aluminium = 160rs/kg
Zinc = 200rs/kg
Sic = 700rs/kg
Auminium oxide = 160rs/kg

8.2 REFERANCES
1. J K M Kwok, S C Lim, “High speed tribological properties of Al/SiC composites: I

Frictional and wear rate characteristics”, Composites Science and Technology, 1999, 59, 55 –
63.
2. J K M Kwok, S C Lim, “High speed tribological properties of Al/SiC composites: II wear

mechanisms”, Composites Science and Technology, 1999, 59, 65 – 75.
3. G Ranganath, S C Sharma, M Krishna, “Dry sliding wear of garnet reinforced

zinc/aluminium metal matrix composites”, Wear, 2001, 251, 1408 – 1413
4. S C Lim, M Gupta, L Ren, J K M Kwok, “The tribological properties of Al-zn/SiC metal

matrix composites”, Journal of material processing and Technology, 1999, 90, 591-596
5. Gencaga Purcek, Temel Savaskan, Samuel Murphy, “Dry sliding friction and wear
properties of zinc based alloy”, Wear, 2002, 252, 894 – 901
6. S Das, “Development of aluminum alloy composites for engineering applications”, Trans.

Indian Inst. Met, 2004, 57, 325 – 334
7. M Ramachandra, K Radhakrishna, “Sliding wear, slurry erosive, and corrosive wear of

aluminium / SiC composite”, Materials Science – Poland, 2006, 24, 333 – 349
8. K H W Seah, S C Sharma, P R Rao, B M Girish, “Mechanical properties of as cast and heat

treated ZA-27 / silicon carbide particulate composite”, Materials and Design, 1995, 16, 277 –
281

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Experimental Investigation of Tribological Properties of ZA43 Hybrid Composite

A composite is a structural material that consists of two or more combined constituents

Department of Mechanical Engineering, BIET Davangere Page 1

1.2 Metal Matrix Composites

alumina (Al2O3), carbon, or graphite.

The reinforcement can be either continuous or discontinuous. Discontinuous MMCs

Typically, ceramics and graphitic materials are used as reinforcement phases in

1.2.1 Particulate Reinforced Metal Matrix Composite

Department of Mechanical Engineering, BIET Davangere Page 3

1.3 GENERAL PROPERTIES OF MMC’s

Department of Mechanical Engineering, BIET Davangere Page 4

Another important advantage of metal matrix alloys is the availability of an excellent

Department of Mechanical Engineering, BIET Davangere Page 5

1.4 APPLICATION OF MMC’s

1.5 ADVANTAGES OF MMCs

 Increased specific strength

 Good corrosion resistance

1.6 LIMITATION OF MMCs

 Composite are heterogeneous

Department of Mechanical Engineering, BIET Davangere Page 6

2.1 Literature Review

Pardeep Sharma,Gulshan Chauhan and Neeraj Sharma “Production of AMC by Stir

Department of Mechanical Engineering, BIET Davangere Page 7

G. B. Veeresh Kumar, C. S. P. Rao, N. Selvaraj, M. S. Bhagyashekar investigated the

N. Radhika, R. Subramanian, S. Venkat Prasad investigated Tribological behaviour of

Department of Mechanical Engineering, BIET Davangere Page 8

2.2 Objective of the Present Work

The objectives of the present work are as follows:

 To prepare the cost-effective MMC material by taking ZA43 as matrix and

Department of Mechanical Engineering, BIET Davangere Page 9

Department of Mechanical Engineering, BIET Davangere Page 10

3.2 Classification of Wear

3.2.1 Abrasive wear

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Department of Mechanical Engineering, BIET Davangere Page 12

3.2.3 Erosive wear

3.2.4 Surface fatigue wear

Department of Mechanical Engineering, BIET Davangere Page 13

3.2.5 Corrosive wear

3.3 Symptoms of Wear

Department of Mechanical Engineering, BIET Davangere Page 14

The following individual properties of each component are given below.

 It is easily formed, machined and can be casted.

 It is light metal, non toxic, non magnetic, and non sparking.

 It has low density, low strength and high ductility.

 It posses high reflectivity and heat conduction properties.

 Young’s modulus: 68.242GPa.

 Thermal conductivity: 237W/m/K.

Department of Mechanical Engineering, BIET Davangere Page 15

Fig 4.1: Aluminium ingots

 It has low melting (692K) point.

 It’s a good conductor of electricity.

 It has a good corrosion resistance property.

Fig 4.2: Zinc metal

Department of Mechanical Engineering, BIET Davangere Page 16

 Aluminium which is in higher percentage responsible for increase in hardness of base

 Composition of ZA43 alloy (wt. %) is given.

Department of Mechanical Engineering, BIET Davangere Page 17

4.4 SILICON CARBIDE

 Low thermal expansion

 High elastic modulus

 Excellent thermal shock resistance

Department of Mechanical Engineering, BIET Davangere Page 18

Fig 4.3 Silicon Carbide