Tribological behavior of as-cast and wrought Al–Mg2Si hybrid composites reinforced by Ti-based intermetallics

Abstract

In this study, the tribological properties of Al–15Mg2Si (AC), Al–15Mg2Si–3TiB2–TiAl3 (C31), and Al–15Mg2Si–5TiB2–4TiAl3 (C54) in-situ composites were evaluated. In the as-cast state, the optimal results were obtained for the C31 sample, where the wear rate and the average coefficient of friction (ACOF) under the load of 60 N decreased by ∼54% and ∼27% compared to those obtained for the AC sample, respectively. Morphological modification of primary and eutectic Mg2Si particles and increasing the volume fractions of TiB2 particles were characterized as key factors for improving wear resistance of C31 sample. On the other hand, the presence of needle-like TiAl3 particles resulted in severe delamination and separation of tribolayer and increased mass loss of C54 sample. Alternatively, the fragmentation and redistribution of eutectic/primary Mg2Si and TiB2/TiAl3 particles during elevated-temperature deofrmation, the reduction of casting defect by thermomechanical processing effects, as well as intense grain refinement by dynamic recrystallization (DRX) improved the mechanical properties of hot-extruded samples and led to a notable enhancement in the load bearing behavior and stability of the formed tribolayer even under high loads. Therefore, the wear mechanism changed from the combination of severe delamination, adhesive, and three-body abrasive wear in the as-cast composites to mild abrasive wear in the hybrid composites subjected to hot deformation by the extrusion process. Consequently, in the optimal condition and under load of 60 N, the wear rate decreased from 29.6 to less than 10 mg/km and ACOF decreased by about 24% in hot-extruded C54 sample compared to the AC sample.

Keywords

• Metal-matrix composites
• Hot working
• Tribological behavior
• Wear mechanism
• Archard equation