Key Takeaways & Executive Findings
- •• Increasing Al3Ti reinforcement content and matrix hardness significantly improves abrasive wear resistance of functionally graded aluminum matrix composites. • Abrasive particle size and applied load are critical parameters influencing wear behavior, with larger particles and higher loads leading to increased wear loss. • The Taguchi method (L27 orthogonal array) effectively optimizes wear testing, providing reliable results with reduced experimental time. • Functionally graded design mitigates the trade-off between wear resistance and fracture toughness, offering a promising approach for aerospace and automotive applications.
Abstract
Aluminum alloys are widely used in industry due to their light weight. These alloys are generally exposed to abrasive wear, which diminishes their effective lifespan. The wear resistance of these alloys is enhanced by adding various reinforcements, however, this enhancement comes at the cost of reduced fracture toughness. This paradox of increased wear resistance versus decreased fracture toughness in aluminum alloys can be resolved by using functionally graded materials (FGMs). This study focuses on the abrasive wear behavior of functional graded aluminum matrix composites reinforced with Al3Ti particles. The wear properties of the composites were investigated by considering the characteristics of the composite such as matrix type and various composite zones, as well as the wear parameters such as abrasive particle diameter, load, sliding speed and distance. Taguchi method was used in the abrasive wear tests in order to get more reliable results in a time-efficient manner. Experiment recipes were created based on the L27(3^6) orthogonal series. As a result of the study, it is observed that the wear resistance of the composites increases with an increase in Al3Ti reinforcement content and hardness of the matrix. In addition, the size of abrasive particles and the applied load are significant factors affecting abrasive wear.
1. Introduction
Aluminum alloys are used across various industrial sectors due to their low density, high corrosion resistance, and excellent formability [1, 2]. As the need for improved performance in aluminum and its alloys grows over time, various methods can be used to enhance their properties. These include the addition of alloying elements, grain refinement, and heat treatment processes [3-6]. One such method is the reinforcement with intermetallic and ceramic compounds such as Al2O3, SiC, AlB2, TiB2, Si3N4, TiO2, and B4C [7-12] to form aluminum matrix composites. Aluminum matrix composites are in great demand in many sectors, especially in the aerospace, automotive and defense industries, due to their high specific strength and high wear resistance.
The reinforcement of intermetallic compounds to the aluminum alloys increases the mechanical properties and wear resistance, but causes a decrease in fracture toughness. This trade-off can be mitigated by utilizing functionally gradient materials (FGMs) in the manufacturing process. FGMs are designed as composites with a gradient in composition and structure to simultaneously improve mechanical performance and fracture toughness in composite materials [13,14]. Researchers have been working hard on the development of FGMs for the last two decades. In this regard, a popular approach is to improve the properties of FGMs by using different reinforcement and matrix materials. Nowadays, Al3Ti particle reinforced aluminum composites have attracted attention due to their low density and excellent mechanical properties [15,16]. In previous studies, it has been reported that aluminum alloys reinforced with Al3Ti exhibited enhanced mechanical and wear properties [17-22]. Chen et al. [19] mentioned that the addition of Al3Ti particles into pure Al, Al-13Si, and Al-17Cu alloys significantly increased the wear resistance of the matrix alloys. Habibolahzadeh et al. [23] found that the addition of Al3Ti to the aluminum matrix increases the abrasion resistance of the composite samples by 4 times compared to pure aluminum. Das et al. [24] reported that the wear resistance of composites increased with the increasing Al3Ti content in peak aged Al-4.5% Cu alloy. Veeresha et al. [25] carried out a study to prepare and characterize Al-Al3Ti composites with 3vol.%, 5vol.% and 7vol.% reinforcement. The results showed that the wear resistance of Al/Al3Ti composites increased with the increase of reinforcement ratio compared to pure aluminum. Savaş and Başer [26] investigated the abrasive wear behavior of functionally graded flake-Al3Ti reinforced aluminum matrix composites using the Taguchi approach. The results showed that the wear losses of composites increased with increasing load, sliding distance, sliding speed, and abrasive particle size, and decreased with increasing Al3Ti particle size. The properties of the functionally gradient composites also depend on the manufacturing method except the reinforced phase and matrix material. Particle reinforced aluminum FGMs can be produced in various methods such as powder metallurgy (PM), thermal plasma spraying, physical vapor deposition (PVD), chem...
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Eylül Tuğçe Yaman Yildiz, Ömer Savaş, Muhammed Soner Başer, Engin Kocaman (2025). Abrasive wear behavior of functionally graded Al3Ti reinforced aluminum matrix composite. China Foundry. https://doi.org/10.1007/s41230-024-3147-1
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Frequently Asked Questions
What is the main objective of this study?
The study aims to investigate the abrasive wear behavior of functionally graded aluminum matrix composites reinforced with Al3Ti particles, focusing on the effects of matrix type, composite zones, and wear parameters such as abrasive particle size, load, sliding speed, and distance.
How was the Taguchi method applied in this research?
The Taguchi method was used to design the abrasive wear experiments based on the L27(3^6) orthogonal array, allowing for efficient and reliable evaluation of multiple factors affecting wear behavior.
What are the key findings regarding wear resistance?
The wear resistance of the composites increases with higher Al3Ti reinforcement content and matrix hardness. Additionally, abrasive particle size and applied load are significant factors affecting abrasive wear.
Why are functionally graded materials (FGMs) used in this context?
FGMs are used to resolve the trade-off between increased wear resistance and decreased fracture toughness in aluminum alloys, by providing a gradient in composition and structure to simultaneously improve both properties.
What are the potential applications of this research?
The findings are relevant for industries such as aerospace, automotive, and defense, where components require high wear resistance and mechanical performance, and the use of FGMs can enhance durability and lifespan.
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