Advanced Functionally Graded Aluminium Hybrid Composite for Tribology Applications

Abstract

Rapidly changing industrial demands urge researchers to majorly focus on improving the tribo mechanical characteristics and corrosion resistance of advanced materials. Engineering applications that are deployed for reciprocal-linear sliding applications report severe wear and reduced service life. The deterioration is not just limited to the sliding component in the long run but is devastating for the counterpart as well. The choice of material is a prime factor for efficient product design and economic engineering. An appropriate variant of material usage plays a significant role in optimizing product development irrespective of industry. Apart from the selection of appropriate alloy grade or composition, the addition of suitable reinforcement plays a crucial role in accommodating and localizing the desired properties within a composite. Functionally Graded Materials (FGM) are still in their early stages of evolution and are identified as customizable materials to incorporate desirable and localized properties. Therefore, the initial phase of this thesis introduces the immense potential and unexplored research areas of Al-Si FGM composites. It also details the selection of base alloy grade, primary and secondary ceramic variants (B4C, TiB2, ZrO2, TiC, and SiC), and explains the appropriate heat treatment cycle utilized in this research for improving the characteristics, along with the manufacturing technique utilized to fabricate the FG alloy and composites. This research focuses on analyzing the possibilities of improving the mechanical and tribological performance of aluminium composites through hybrid ceramic reinforcing. The next phase of this thesis deals with the studies on physical metallurgy, mechanical and advanced characterization of developed FG alloy and composites. It compares the tribo-mechanical performance and worn surface morphology of FG alloy, mono-composite, and hybridcomposites at as-cast and heat-treated conditions. Difference in hybrid ceramic densities and centrifugal force was combined,