2010-wear-high temperature wear behavior of al–4cu–tib2 in situ composites

8/12/2019 2010-Wear-High Temperature Wear Behavior of Al4CuTiB2 in Situ Composites

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Wear 268 (2010) 12661274

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Wear

j ou rna l ho mep age : www.e l sev i e r. com/ loca t e /wea r

High temperature wear behavior of Al4CuTiB 2 in situ composites

S. Kumar, V. Subramanya Sarma, B.S. Murty

Department of Metallurgical and Materials Engineering, Indian Institute of Technology Madras, Chennai 600 036, Tamil Nadu, India

a r t i c l e i n f o

Article history:Received 9 June 2009Received in revised form 7 January 2010Accepted 13 January 2010Available online 25 January 2010

Keywords:Sliding wearThermal effectsMetal matrix compositesHigh temperature

a b s t r a c t

The effect of sliding temperature and load on the wear behavior of Al4Cu alloy and Al4CuTiB 2 in situcomposites was studied in this paper. The wear resistance of the Al4Cu alloy increased with increase inwt.% of reinforcement TiB 2 particles at all temperatures and loads. The transition in the wear mode from

mild to severe wear was strongly inuenced by the addition of TiB 2 particles. The Al4Cu alloy showeda transition from mild to severe wear at a load of 80 N and at a sliding temperature of 100 C. But withthe addition of 5 and 10 wt.% of in situ TiB2 particles to the Al4Cu matrix, the transition temperaturesare increased to 200 and 300 C and the loads are increased to 100 and 120 N, respectively. Analysis of wear surfaces by scanning electron microscopy revealed the transition in wear mode. It was observedthat at elevated temperature the predominant wear mechanisms for the Al4Cu alloys are adhesion andmetal ow, whereas for Al4CuTiB 2 composites oxidation, delamination and metal ow are the mostdominant wear mechanisms.

2010 Elsevier B.V. All rights reserved.

1. Introduction

Aluminium based metal matrix composites (MMCs) has poten-tial applications in automobile andaerospace industries, where thecomponents are subjected to severe surface degradation. Al basedMMCsare wellknown for their superior tribologicalbehaviorwhencompared to the base alloy [1] . In recent studies, it was shown thatAl based in situ MMCs (reinforcement phases synthesisduring cast-ing) have better properties and performance when compared to exsitu MMCs [2,3] . The superior behavior of these in situ compositesis due to good matrixreinforcement interface and smaller rein-forcement size (


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synthesis and heat treatment of these composites can be foundelsewhere [57] .

The high temperature dry sliding wear tests were carried outon a high temperature pin-on-disc wear testing machine (TR-2HT-M3, DUCOM, Bangalore, India). The pin (8 mm in diameterand 12 mm in height) slides against steel (ball bearing steel) disc.The wear tests were carried on the peak aged alloy and compos-ites. The sliding velocity and sliding distance were kept constantin all the experiments at 1 m s 1 and 1 km, respectively. Theapplied load was varied from 40 to 120 N and the temperaturewas varied from room temperature (RT) to 300 C. The pin anddisc were heated uniformly and after the temperature is stabi-lized the wear test was started. Further experiment details can be

found from an earlier report by the authors [9]. The wear testswere carried out in ambient atmosphere with the humidity of about 80% and a new disc was used for each experiment. The pinand disc were polished and cleaned to get uniform average sur-face roughness (Ra) of about 0.410.62 m which was measuredusing Perthometer (M2 Mahr GMBH, Germany). The wear rate isdened as volume loss divided by sliding distance, and the vol-ume loss is obtained from the ratio of weight loss to the densityof the sample. The coefcient of friction was measured continu-ously using computer aided integration system. The worn surfaceof the pin and disc were analysed using optical microscopy andFEI Quanta 200 scanning electron microscope (SEM) with EDAXenergy dispersive spectroscopy (EDS). The subsurface of wear scar

Fig. 1. Effect of load on the wear rate of Al4Cu alloy and composites at different temperature (a) RT, (b) 100

C, (c) 150

C, (d) 200

C and (e) 300

C.


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is analysed by cross-sectioning the worn surface along the slidingdirection,

3. Results and discussion

Fig. 1(ae) shows the sliding wear behavior of Al4Cu alloy andAl4CuTiB 2 composites at different loads and temperatures. Thewear resistance of Al4CuTiB

2 in situ composites is found to be

superior to that of Al4Cu alloy under all sliding conditions. Thewear resistance of Al4Cu alloy increased with the addition of TiB2 particles and at room temperature, the wear rate of Al4Cualloy is reduced by 60-65% with the addition of 10wt.% of TiB 2particles. This can be attributed to the increase in hardness dueto the change in microstructure (grain size, reinforcement andprecipitation) of Al4Cu alloy with the addition of in situ TiB2 par-ticles. The peak aged hardness of Al4Cu alloy, Al4Cu5TiB 2 andAl4Cu10TiB 2 are 88,112 and136 HV5, respectively. It was foundthat the addition of in situ TiB2 particles to Al4Cu alloy signi-cantly increases the aging kinetics of base alloy and the increasein properties of these Al4CuTiB 2 composites can be attributed tograin boundary strengthening, particulate strengthening and pre-cipitation strengthening [4,5,7] . Similar improvement in the agingkinetics and wear resistance was observed in the composites whensubjectedto rollingand subsequentheattreatment [6] . Ontheotherhand, Tee et al. [12] did not observe improvement even after theincorporationof 15 vol.% of insitu TiB2 particles. Thiswas attributedto the presence of TiAl 3 intermetallic phase. Wu et al. [13] reportedthat thepresence of TiAl 3 is detrimental to the wear resistance of Almatrix alloy and showed that the wear resistance of AlTiB 2 in situcomposites improved with decrease in TiAl 3 phase fraction. This isbecause the large TiAl 3 blocky particles during sliding were subjected to fracture and resulted in a particle pull out. The increasein wear resistance observed in the present study is attributed tothe absence of TiAl 3 phase. The presence of only TiB 2 is conrmedby XRD analysis on the extracted in situ formed particles by dis-solving the Al4Cu matrix from the composite and this result is

reported elsewhere [5] . During wear of composites, the interactionbetween the matrix and counterface will be controlled by the rein-forcement. The interaction here refers to the adhesion phenomenathat exist between the asperities of soft matrix and hard counter-face. Under load, the contact asperities of soft (pin) and hard (disc)surfaces undergo deformation which results in cold welding and istermed as adhesion. When these surfaces are subjected to sliding,these cold welded asperities get detached and results in metal lossand such loss of metal is termed as adhesive wear. With increas-ing reinforcement phase, the amount of soft matrix asperities thatare in contact with hard counterface reduces and this contributesto the increased wear resistance. In the present case the interac-tion between steel and -Al asperities is reduced with increasingthe amount of TiB 2 particles. This can be explained based on the

microstructure [5] , i.e., the area fraction of the soft -Al decreaseswith increase in the amount of TiB 2 particles, thereby resulting inthe higher wear resistance of the in situ composites.

In addition to the amount of the TiB 2 particles, the wear rate isalsodependenton the applied load. Fig.1(ae)alsoshowsthe effectof applied load on the wear behavior of Al4Cu alloy with differ-ent amounts of the reinforcement andtemperatures. The wear rateincreases with increasing load at all temperatures. This is due toincrease in the deformation of the matrix with increase in appliedload. However, the extent of deformation due to applied load isreduced with increase in the TiB 2 content. Similarly, the wear rateis much lower forthe composites at alltemperatures in comparisonto the base alloy. This improvement is attributed to the improvedstrength/hardness of the composites due to grain renement, pre-

cipitationstrengtheningand dispersionstrengthening.PrasadaRao

Fig. 2. Normalized wear rate asa functionof TiB 2 amount at differenttemperaturesand at 40N load.

etal. [14] clearly demonstratedthe improvementin wearresistanceand load bearing capacity with grain renement. As mentionedabove, the severity of the wear damage increases with increase intemperature ( Fig. 1). In severe wear, bulk of the metal gets trans-ferredfrom the pinto thesteel counterface duringsliding, whereasin mild wear regime, thepin gets oxidized anddelaminatedto formmechanically mixed layer (MML) and sliding occurs without anybulkmetaltransfer.Atthetestingtemperatureof100 C,theAl4Cualloy shows severe mode of wear at 80N and further increase insliding temperature to150 C (Fig.1(c))and200 C (Fig.1(d )) lowersthe mild to severe wear transition load to 60 and 40 N, respec-tively. The temperature at which mild to severe wear transitionoccurred shifted to higher temperatures with increasing amountof TiB2 particles. The transition behavior of alloy and composites isstrongly dependenton applied load and sliding temperature. Singhand Alpas [15] also reported similar type of transition behavior in

6061 AlAl 2 O3 composites.To study the effect of TiB 2 particles on the wear behavior of

Al4Cu alloy the normalized wear rate (ratio of the wear rate of composites to the wear rate of matrix alloy) was evaluated ( Fig. 2).With increase in TiB 2 content, the normalized wear rate decreasedat alltemperatures used in the present study.It is also interestingtonote that thenormalizedwear rate decreasedwith increase in tem-perature for a given amount of TiB 2 . This clearly explains that theTiB2 particles in the Al4Cu alloy are more effective in resistingthewear at high temperature in comparison to the room temperature.This can be attributed to the improvement in thermal stability of Al4Cu alloywiththe additionof TiB 2 particles. It is wellestablishedthat the coefcient of thermal expansion (CTE) of Al is reduced bythe addition of hard ceramic phase [1619] . The CTEs for Al4Cu

alloy and TiB 2 are 26.9 10 6

and 4.6 10 6

C 1

, respectively,and from rule of mixtures, the calculated CTEs for Al4Cu5TiB 2Al4Cu10TiB 2 composites are 26.1 10 6 and 25.3 10 6 C 1 ,respectively, and these are smaller than the matrix alloy. Thereforein thepresentcase, thedimensionalstability of matrix Al4Cu alloy,which has high CTE, is improved due to the presence of stable insitu reinforcement, TiB 2 . With increase in sliding temperature, thematrix alloy is softened resulting in transfer of metal to the steelcounterface, but with the addition of TiB 2 particles, the softeningtendency of the matrix alloy is reduced resulting in increased wearresistance. It is also interesting to note that the wear resistance of the composites is retained even after exposure to a temperatureof 300 C (which is much higher than the peak aging temperatureof 170 C), whereas the peak aged Al4Cu alloy undergoes severe

wearat100

Catanappliedloadof80N.Itcanbeconcludedthatthe


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Fig. 3. Average coefcient of friction ( ) of Al4Cu and composites as the function of load at different temperatures (a) RT, (b) 100 C, (c) 150 C, (d) 200 C and (e) 300 C.

presence of hard ceramic particles (TiB 2 ) in Al4Cu matrix resistsmetal ow at higher temperature and results in improved wearresistance at high temperatures. Huang et al. [20] clearly demon-

strated the presence of TiB 2 in situ particles improves the creepresistance of the matrix Al alloy.Theeffects of load andtemperature on the average coefcient of

friction ( ) of Al4Cu alloy and composites were plotted in Fig. 3.The coefcient of friction ( ) of the Al4Cu alloy and compositesincreased with increase in load and temperature. In all the cases, insitu composites showed lower values when compared to matrixalloy. Similar behavior was also observed in Al7Si alloy based insitu composites [8,9] . Thisclearlyshows that theformationof ultra-ne in situ particles lowers the coefcient of friction of Al4Cualloymatrixandthisis attributed to thegoodparticlematrix inter-face, improved dispersion and smaller particle size [21] . Min et al.[22] compared the of AlTiB2 composites with AlSiC compos-ites and found that AlTiB 2 composites showed lower coefcient

of friction (

0.160.17) when compared to AlSiC composites

( 0.70). It was observed that of Al4Cu alloy increases withincrease in temperature due to the severe transfer of metal to thecounterface. However, Al4Cu composites show a drop in with

increase in temperature up to 200

C.Thisdropin for the Al4Cucomposites can be attributed to the improved thermal stability of composites (due to the presence of TiB 2 particles) and formationof iron oxide layer between the mating surfaces.

Fig. 4 shows the wear surface of Al4Cu alloy at 40N load testedat room temperature. The wear surface shows ( Fig. 4(a)) distinctparallel grooves throughout the worn surface. These grooves wereformed due to the ploughing tendency of steel asperities. Theaggressiveness of the ploughing increased with increase in theapplied load. The wear surface of the Al4Cu alloy did not showgrooves, when the sliding temperature was increased to 100 C(Fig. 4(b)). Grooves are formed over the soft material (Al4Cualloy) by the ploughing of sliding hard asperities (steel disc).During ploughing, the metal from the grooves are displaced by the

sliding asperities along the side of the grooves, but at high sliding


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Fig. 4. Wear surface of Al4Cu alloy after sliding at (a) RT and (b) 100 C with the load of 40 N. The arrow mark shows the sliding direction.

temperature, the displaced soft metal has the tendency to owback. This result in the worn surface to have shallow grooves whencompared to the sample subjected to wear at room temperature.

Therefore, the wear scars of the Al4Cu alloy worn at 100

C donot show steep grooves. When the temperature is increased to

200 C, there is a bulk transfer of metal from the Al4Cu alloy tothe steel surface. This process of bulk metal transfer is termed assevere mode of wear and is the reason for the observed increase in

the . Fig. 5(a) clearly shows the metal ow on the worn surface of Al4Cu alloy and Fig. 5(c) shows the deposition of Al4Cu alloy on

Fig. 5. (a)SEM micrograph, (b)EDS analysis on thewornsurface of Al4Cualloy, (c)SEM micrograph and(d) EDSanalysisof steel disc at temperature of 200 C withtheload

of 40N.


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Fig. 6. Longitudinal cross-section (parallel to the sliding direction) of the wear scar of Al4Cu alloy tested at 200 C (a) low and (b) high magnication.

Fig. 7. Wear surface on Al4Cu10TiB 2 in situ composite after sliding at (a) RT and (b) 200

C with the load of 40 N and (c) EDS analysis on 200

C sample.


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the counterface. The EDS analysis on the worn surface of Al4Cualloy ( Fig. 5(b)) does not show Fe, further conrming the absenceof mechanical mixed layer. Elemental analysis on steel surface(Fig. 5(d)) shows the presence of Al and Cu without any Fe peak,which indicates that Al alloy is coated as a thick layer on the weartrack of the steel surface. Further, thecross-sectionof worn surface

(Fig. 6(a)) shows that Al4Cu alloy has undergone extrusion atelevated temperature and the high magnication image ( Fig. 6(b))shows no macroscopic evidence for mechanically mixedlayer. Thisis consistent with SEM ( Fig. 5(a)) and EDS ( Fig. 5(b)) analysis onwear scars of worn surface. This conforms that, due to instability of the alloy at high temperature, the bulk of metal starts to ow along

Fig. 8. (a and b) SEM micrographs and (c) EDS analysis on the worn surface of Al4Cu10TiB 2 composites at 200 C with 120 N.

Fig. 9. (a) SEM micrograph and (b) EDS analysis on the worn surface of steel counterface with Al4Cu10TiB 2 composites at 200

C with 120 N.


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the sliding direction, as a result (a) part of the metal adheres to thesteel counterface and (b) part of the metal is extruded to the rearend of the sliding surface (pin). Further, due to repeated sliding of the pin on the same wear track of steel counterface, the adheredmatrix alloy on steel counterface starts to pile-up on the front of sliding surface ( Fig. 6(a)). From the analysis of wear surface it canbe concluded that at room temperature,the observed wear mecha-nism of Al4Cualloyis abrasion whereas at highertemperature thepredominant wear mechanism is adhesion followed by metal ow.

Thewearsurfaceof Al4Cu10TiB 2 in situ composites areshownin Fig. 7. At room temperature and at load of 40N, the wear sur-face of Al4Cu10TiB 2 composite shows shallow grooves runningparallel to the sliding direction ( Fig. 7(a )). The wear surface of theAl4Cu10TiB 2 composites afterslidingat anelevated temperatureof 200 C still shows the grooves ( Fig. 7(b)), which is in contrast tothat observed in Al4Cu alloy ( Fig. 5(a )). This is attributed to thedimensional stability of matrix due to the presence of TiB 2 parti-cles. Further, theEDS analysis ( Fig. 7(c)) on the worn surface shows

Fig. 10. Longitudinal cross-section (parallel to the sliding direction) of the wear scar of Al4Cu10TiB 2 in situ composites tested at 200 C with 120 N: (a) low, (b) highmagnication and (c) trace diagram from (b) to show various regions below the worn surface.

Fig. 11. (a) SEM micrograph and (b) EDS analysis on the worn surface of Al4Cu10TiB 2 in situ composites at 300

C with 100 N.


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the evidence of Fe and O. When the load and temperature of thetesting were increased to 120 N and 200 C, respectively, the wornsurface in the composite clearly shows delamination ( Fig. 8(a)). Ahigher magnication view of the delaminated region shows thepresence of small particles ( Fig. 8(b)) and EDS analysis ( Fig. 8(c))conrms the presence of Fe and O 2 . The presence of iron oxideparticles on the worn surface resembles the delamination of MML,which is formed during continuous sliding of the pin over the steeldisc in which the mating surfaces were exposed to the elevatedtemperature and high load. The worn surface on the steel coun-terface ( Fig. 9(a)) also shows the presence of Fe, Ti, Cu, Al and O(Fig. 9(b)) on the wear track, which also conrms the formation of MML. Formationof iron oxide layer on worn surface was also foundby Singh and Alpas [23] and they reported that iron oxide layerwill reduce the coefcient of friction and wear rate of the com-posites by acting as in situ lubricant. To understand this further,the subsurface analysis was carried out on the worn pin speci-men by cross-sectioning it vertically along the sliding direction.The cross-sectionedmicrostructure of Al4Cu10TiB 2 wornsurface(Fig. 10 (a)) shows very ne extruded portion at rear (compared tothe Al4Cu matrix alloy, Fig.6 (a )) andthehighmagnication image(Fig. 10 (b)) reveal the existence of MML and deformed region. Thene extruded part in composites is attributed to the presence of TiB2 particles, which reduces the softening tendency of the matrixwhen subjected to elevated temperature wear process. The obser-vance of MML only in composite is attributed to the presence of hard ne TiB 2 particles, whichabrade thesteel counterface andtheresultant debris (generally of Fe and Fe-oxide) get in between themating surfaces where it is mixed with soft matrix during subse-quentslidingto form MML. Fig. 10 (c) showsa schematicof differentregions on the wornsubsurface microstructure of Fig. 10 (b ). BellowMML, there is a region, wherethe TiB 2 particlesare welldistributedwithin the matrix and this is due to the high shear strain experi-enced locally during the deformation and termed as shear mixedlayer. In this region, most of the ex situ composites reinforcementsfractured to ne particlesand get distributed uniformly [23,24] . Ontheother hand, in the present case since the in situ formed TiB 2 par-

ticles are less than 1.5 m in size, the particles did not fracture andare distributed uniformly beneath the MML region. Further belowthe shear mixed region, plastic ow line can be clearly observed(deformedlayer) where the TiB 2 particles are aligned in such a waythat ow lines progressively bend towards the sliding direction asmoving towards the worn surface. The alignment of TiB 2 particlesalong theow linerepresents theplasticdeformationundergonebysubsurface along the shear strain direction. Near the un-deformedregion of the composite pin, the shear strain is minimum, but as itapproaches the worn surface, the shear stain increases and even-tually reaches maximum near to the worn surface. Such ow linesare not observed in the Al4Cu alloy because of the absence of TiB 2particles. Thereforefrom thepresentwearscar analysison thecom-posites it can be summarised that at high temperature, oxidation

and delamination were the dominant wear mechanisms, whereasat room temperature the predominant wear mechanism for thecomposites (up to 10 wt.% TiB 2 ) is adhesion and abrasion. Whenthe temperature is increased to 300 C and at a load of 120N, theAl4Cu10TiB 2 in situ composites undergo transition from mild tosevere wear and the wear surface ( Fig. 11 (a)) is similar to type of metal ow observed in Al4Cu alloy at 100 C (Fig. 5(a)) and EDSanalysis ( Fig. 11 (b )) conrms theabsence of Fe on the worn surface.

4. Conclusions

The room temperature and elevated temperature wear resis-tance of Al4Cu alloy is increased with the addition of TiB 2 in situ

particles. Coefcient of frictionof these in situ composites are lower

than the base alloy.The wear rate of alloy andcompositesincreasedwith increase in applied load and sliding temperature. The mild tosevere wear mode transition in Al4Cu alloy is dependent on theapplied load, temperature and TiB 2 content. Normalized wear ratedecreases with increase in temperature for the given amount of TiB2 , which clearly indicates that the TiB 2 particles in the Al4Cualloy are more effective in resisting the wear at high temperaturethan at room temperature. At elevated temperature, the predom-inant wear mechanisms in Al4Cu alloy are adhesion and metalow, whereas in Al4CuTiB 2 composites oxidation, delaminationand metal ow are the dominant wear mechanisms.

Acknowledgement

The authors are thankful to Naval Research Board, Governmentof India, for funding this research work.

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2010-wear-high temperature wear behavior of al–4cu–tib2 in situ composites

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