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Short communication

Application of Taguchi techniques to study dry sliding wear


behaviour of metal matrix composites
S. Basavarajappa
a,
*
, G. Chandramohan
a
, J. Paulo Davim
b
a
Department of Mechanical Engineering, PSG College of Technology, Coimbatore 641 004, India
b
Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal
Received 11 July 2005; accepted 3 January 2006
Available online 3 March 2006
Abstract
Aluminium metal matrix composites reinforced with SiC and graphite (Gr) particles was prepared by liquid metallurgy route. Dry
sliding wear behaviour of the composite was tested and compared with Al/SiCp composite. A plan of experiments based on Taguchi
technique was used to acquire the data in a controlled way. An orthogonal array and analysis of variance was employed to investigate
the inuence of wear parameters like as normal load, sliding speed and sliding distance on dry sliding wear of the composites. The objec-
tive was to investigate which design parameter signicantly aects the dry sliding wear. It shows that graphite particles are eective
agents in increasing dry sliding wear resistance of Al/SiCp composite.
2006 Elsevier Ltd. All rights reserved.
Keywords: Dry sliding wear; Taguchi technique; Analysis of variance
1. Introduction
Metal matrix composite materials are advanced materi-
als, which combine tough metallic matrix with a hard
ceramic or soft reinforcement to produce composite mate-
rials [1,2]. These materials have superior properties com-
pared to the monolithic materials and can be tailarable
to a specic applications [3,4]. Metal matrix composite
materials show advantages in a great number of specic
applications (aircraft, automobile, machines) due to their
high specic strength and stiness, wear resistance and
dimensional stability. The most popular hard reinforce-
ments are silicon carbide, alumina and soft reinforcement
as graphite [57]. These materials have shown to have dif-
ferent strengthening mechanisms when compared to con-
ventional materials or continuous reinforced composites
[8]. Thus, much research, both experimental and analyti-
cal, has been performed to gain a better understanding
of mechanical behaviour of these materials and their
excellent wear resistance. The presence of hard reinforce-
ment phases, particulates, bres or whiskers has endowed
these composites with good tribological (friction and
wear) characteristics. The wear resistance with good spe-
cic strength and modulus make them good candidate
for many engineering situations where sliding contact is
expected. Sannino et al. [9] undertook an extensive review
work on dry sliding wear characteristics of aluminium
alloy based composites, and abrasive wear behaviour wear
by Deuis et al. [10]. In their study and discussion, the
eect of reinforcement volume fraction and size, sliding
distance, applied load, sliding speed, hardness of the
counter face and properties of the reinforcement phase,
that inuences the dry sliding wear behaviour of this
group of composites were examined in greater detail.
The sliding wear rate and wear behaviour were reported
to be inuenced by several wear parameters [1116].
Lim et al. [17] studies the tribological behaviour of Al
Cu/SiCp metal matrix composites and reported with
increasing the mechanical properties, wear resistance also
0261-3069/$ - see front matter 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2006.01.006
*
Corresponding author. Tel.: +91 422 2572177/2572477; fax: +91 422
2573833.
E-mail address: basavarajappas@yahoo.com (S. Basavarajappa).
www.elsevier.com/locate/matdes
Materials and Design 28 (2007) 13931398
Materials
& Design
be increased drastically, and it will eect the counter face.
Mohan et al. [16], under the conclusion that the incorpo-
ration of graphite after 1% slightly reduces the mechanical
properties, but enhances the wear resistances of the mate-
rial. The incorporation of graphite in the composite
smears on the surface and forms a layer that reduces
the wear. The wear resistance of the graphitic composites
is more due to the inherent property of the natural lubri-
cation. The ceramicgraphite hybrid composites demon-
strated that wear resistance can substantially increases
without loosing properties compared to the Al/SiCp com-
posite [1820].
Sahin [21] conducted an abrasive wear test on Al2011
alloy with 510 wt% SiCp content with 3264 lm reinforce-
ment size. Factorial designs of experiments were used to
assess the contribution of applied load, sliding distance
and particle size. The abrasive wear was the response of
the material running against SiCp and Al
2
O
3
emery papers
under dierent sliding conditions. He concluded that the
wear rate of the matrix and the composite materials
increased with increasing the abrasive size, applied load
and sliding distance when SiC abrasive paper was used.
However, the wear rate increased with increasing abrasive
size and applied load and decreased with increasing sliding
distance when the Al
2
O
3
emery paper was selected. Esteban
Fernandez et al. [22] described a multi-factor based on
experiments that has been applied to investigating an abra-
sive wear system of Ni-based alloy coatings with and with-
out WC reinforcement. They reported that abrasive grain
size exerted the greatest eect on abrasive wear followed
by reinforcement. The applied load and the environment
were similarly found to have minor eect. The addition
of WC reinforcement particles improved wear resistance
of NiCrBSi alloy coating. Increasing abrasive grain size
led to obviously greater wear, especially for NiCrBSi with-
out WC. Wear loss was increased with applied load, but
showed unclear tendencies as regards the inuence of envi-
ronments. Mondal et al. [23] studied the two-body abrasive
wear behaviour of a cast aluminium alloy 10 wt% Al
2
O
3
particle composite was studied at dierent loads (17 N)
and abrasive sizes (3080 lm). The wear behaviour was
predicted through statistical analyses of the measured wear
rate at dierent operating conditions. The developed model
qualitatively hold good for alloy and individual variables
such as load and abrasive size on the wear resistance of
the composites. They concluded along with reinforcement
size and the load the interaction factors also quite signi-
cant and one must take into consideration these terms for
determining the wear rate of these materials.
In view of the above, an attempt is made in this investi-
gation to study the eect of applied load, sliding speed and
sliding distance on dry sliding wear behaviour of the Al/
SiCp and Al/SiCpGr composites using Taguchi design
of experiments. The analysis of variance was employed to
nd the percentage of inuence of various factors and its
interaction on dry sliding wear of the composites.
2. Taguchi techniques
Taguchi technique is a powerful tool for the design of
high quality systems [2426]. It provides a simple ecient
and systematic approach to optimize designs for perfor-
mance, quality and cost. The methodology is valuable
when design parameters are qualitative and discrete. Tagu-
chi parameter design can optimize the performance charac-
teristics through the setting of design parameters and
reduce the sensitivity of the system performance to source
of variation [26,27]. This technique is multi-step process,
which follow a certain sequence for the experiments to
yield an improved understanding of product or process
performance. This design of experiments process made up
of three main phases: the planning phase, the conducting
phase and analysis interpretation phase. The planning
phase is the most important phase one must give a maxi-
mum importance to this phase. The data collected from
all the experiments in the set are analyzed to determine
the eect of various design parameters. This approach is
to use a fractional factorial approach and this may be
accomplished with the aid of orthogonal arrays. Analysis
of variance is a mathematical technique, which is based
on a least square approach. The treatment of the experi-
mental results is based on the analysis of average and anal-
ysis of variance [28,29].
3. Experimental procedure
3.1. Materials
Aluminium alloy 2219 was used as the matrix material in the present
investigation and present following the chemical composition (%):
Si = 0.2 max, Fe = 0.3 max, Cu = 5.86.8, Mn = 0.20.4, Mg = 0.02
max, Zn = 0.1 max, V = 0.050.15, Ti = 0.020.1, Zr = 0.10.25,
Al = balance. This matrix was chosen, since it provides excellent combina-
tion of strength and damage tolerance at elevated and cryogenic tempera-
ture. Two types of composites are used, one with 15 wt% of SiCp
reinforcement of size 25 lm and a second one with 15% SiCp reinforce-
ment, 3 wt% of graphite is added with a particle size of 45 lm. Liquid met-
allurgy method was used to fabricate the composites which was used by
the other researchers [3032].
3.2. Plan of experiments
The experiments were conducted as per the standard orthogonal array.
The selection of the orthogonal array is based on the condition that the
degrees of freedom for the orthogonal array should be greater than or
equal to sum of those wear parameters [2629]. In the present investiga-
tion, an L
27
orthogonal array was chosen, which has 27 rows and 13 col-
umns as shown in Table 1. The wear parameters chosen for the experiment
was (i) sliding speed, (ii) load and (iii) sliding distance. Table 2, indicates
the factors and their level. The experiment consists of 27 tests (each row in
the L
27
orthogonal array) and the columns were assigned with parameters.
The rst column was assigned to sliding speed (S), second column was
assigned to load (L), and fth column was assigned to sliding distance
(D) and the remaining columns were assigned to their interactions. The
response to be studied was the wear with the objective of smaller is the bet-
ter. The experiments were conducted as per the orthogonal array with level
of parameters given in each array row. The wear test results were subject
to the analysis of variance.
1394 S. Basavarajappa et al. / Materials and Design 28 (2007) 13931398
3.3. Experimental set up and procedure
A pin-on-disc test apparatus shown in Fig. 1 was used to investigate
the dry sliding wear characteristics of the composite as per ASTM G99-
95 standards. The wear specimen with 10 mm of diameter and 30 mm
height was cut from as cast samples machined and then polished metallo-
graphically. The block diagram shown in Fig. 2 shows the step-by-step
procedure used to evaluate the dry sliding wear. The initial weight of
the specimen was measured in a single pan electronic weighing machine
with least count of 0.0001 g. During the test the pin was pressed against
the counter part rotating against EN32 steel disc with hardness of
65 HRc by applying the load. After running through a xed sliding dis-
tance, the specimens were removed, cleaned with acetone, dried and
weighed to determine the weight loss due to wear. The dierence in the
weight measured before and after test gives the dry sliding wear of the
composite specimen and then the volume loss was calculated. The wear
of the composites was studied as a function of the sliding distance, applied
load and the sliding speed.
4. Results and discussions
4.1. Statistical analysis
The experiments were conducted with an aim of relat-
ing the inuence of sliding speed (S), applied load (L) and
sliding distance (D) with dry sliding wear of both the
composites under study. On conducting the experiments
as per the orthogonal array, the dry sliding wear results
for various combinations of parameters were obtained
and shown in Table 3. The purpose of the statistical anal-
ysis of variance (ANOVA) is to investigate which design
parameter signicantly aects the wear characteristic.
Based on ANOVA the optimal combinations of the pro-
cess parameters are predicted. This analysis is carried
out for level of signicance of 1% (i.e., the level of con-
dence 99%) [26,27]. Tables 4 and 5 show the results of
ANOVA analysis for both SiCp and SiCpGr reinforced
composite materials, respectively. It can be observed from
the ANOVA analysis that the (i) sliding speed, (ii) load
and (iii) sliding distance on dry sliding wear of the com-
posite. The interaction between the above factors does
not have signicant inuence on the wear of both the
composites under study. The column 5 of the ANOVA
analysis of SiCp reinforced composite (Table 4) indicates
the percentage contribution (p) of each factor on the total
variation indicating their degree of inuence on the result.
If can be observed from Table 4 that the sliding distance
(p = 57.57%), load (p = 24.34%) and sliding speed
(p = 6.8%). However, the interaction between sliding
speed and load is (p = 2.15%) and other factors are min-
imum. The pooled error is 6.64%. In the case of Graphitic
hybrid composite, the column 5 of the ANOVA analysis
in Table 5 indicates the percentage contribution (p) of
each factor on the total variation indicating their degree
of inuence on the result. It can be observed from Table
5 that the sliding speed (p = 57.24%) load (p = 22.58%)
and sliding speed (p = 9.66%). However, the interactions
between the factors are minimum. The pooled error is
5.32%. In Al/SiCp and Al/SiCpGr composites, the dry
sliding wear parameters have statistical and physical sig-
nicance. The interactions between the parameters in both
the materials have statistical signicance but do not have
any physical signicance (error > percentage contribution
of interactions). The percentage of inuence of each fac-
tor is more or less same and it indicates that the incorpo-
Table 1
Orthogonal array L
27
(3
13
) of Taguchi [24]
L
27
(3
13
) test 1 2 3 4 5 6 7 8 9 10 11 12 13
1 1 1 1 1 1 1 1 1 1 1 1 1 1
2 1 1 1 1 2 2 2 2 2 2 2 2 2
3 1 1 1 1 3 3 3 3 3 3 3 3 3
4 1 2 2 2 1 1 1 2 2 2 3 3 3
5 1 2 2 2 2 2 2 3 3 3 1 1 1
6 1 2 2 2 3 3 3 1 1 1 2 2 2
7 1 3 3 3 1 1 1 3 3 3 2 2 2
8 1 3 3 3 2 2 2 1 1 1 3 3 3
9 1 3 3 3 3 3 3 2 2 2 1 1 1
10 2 1 2 3 1 2 3 1 2 3 1 2 3
11 2 1 2 3 2 3 1 2 3 1 2 3 1
12 2 1 2 3 3 1 2 3 1 2 3 1 2
13 2 2 3 1 1 2 3 2 3 1 3 1 2
14 2 2 3 1 2 3 1 3 1 2 1 2 3
15 2 2 3 1 3 1 2 1 2 3 2 3 1
16 2 3 1 2 1 2 3 3 2 1 2 3 1
17 2 3 1 2 2 3 1 1 2 3 3 1 2
18 2 3 1 2 3 1 2 2 3 1 1 2 3
19 3 1 3 2 1 3 2 1 3 2 1 3 2
20 3 1 3 2 2 1 3 2 1 3 2 1 3
21 3 1 3 2 3 2 1 3 2 1 3 2 1
22 3 2 1 3 1 3 2 2 1 3 3 2 1
23 3 2 1 3 2 1 3 3 2 1 1 3 2
24 3 2 1 3 3 2 1 1 3 2 2 1 3
25 3 3 2 1 1 3 2 3 2 1 2 1 3
26 3 3 2 1 2 1 3 1 3 2 3 2 1
27 3 3 2 1 3 2 1 2 1 3 1 3 2
Table 2
Process parameters with their values at three levels
Level Sliding speed, S (m/s) Load, L (N) Sliding distance, D (m)
1 1.53 9.81 500
2 3.06 19.6 1000
3 4.59 39.2 1500
Fig. 1. The schematic view of the pin on disc apparatus used in this study.
S. Basavarajappa et al. / Materials and Design 28 (2007) 13931398 1395
ration of graphitic composite under study will inuence in
increasing the wear resistance compare to the SiCp rein-
forced composite at all conditions but it will not make
any impact over the change in percentage of inuence
of the individual wear parameters.
4.2. Wear mechanism
The asperities of pin and counter face which are in con-
tact are subjected to relative motion under the inuence of
applied load. Initially both the surfaces are associated with
a large number of sharp asperities and contact between
them takes place primarily at these points. Under the inu-
ence of applied load and speed, the asperities in each sur-
face come in contact with each other and they are either
plastically deformed or remain in elastic contact. As the
asperities are very sharp in nature, the eective stress on
these sharp points may be more than the elastic stress
and then all these sharp asperities are plastically deformed
at their contact points except the partially projected points
of the reinforcement. The plastically deformed surface will
As cast
specimen
Machining
Surface
preparation
Final
weight
Test
Initial
weight
Difference
Wear
Fig. 2. Step by step procedure used to evaluate the dry sliding wear of unreinforced alloy and composites.
Table 3
Orthogonal array of Taguchi for wear
Test Sliding
speed,
S (m/s)
Load,
L (N)
Sliding
distance,
D (m)
Wear
SiCp,
WR (mm
3
)
Wear
graphitic,
WR (mm
3
)
1 1.53 9.81 500 1.08 0.8
2 1.53 9.81 1000 1.6 1.34
3 1.53 9.81 1500 2.01 1.8
4 1.53 19.6 500 1.6 1.44
5 1.53 19.6 1000 2.19 2.1
6 1.53 19.6 1500 3.0 2.8
7 1.53 39.2 500 1.55 1.4
8 1.53 39.2 1000 2.8 2.04
9 1.53 39.2 1500 3.8 3.41
10 3.06 9.81 500 0.82 0.6
11 3.06 9.81 1000 1.39 1.01
12 3.06 9.81 1500 1.98 1.6
13 3.06 19.6 500 1.06 0.91
14 3.06 19.6 1000 1.7 1.48
15 3.06 19.6 1500 2.1 1.8
16 3.06 39.2 500 1.4 1.00
17 3.06 39.2 1000 2.22 1.8
18 3.06 39.2 1500 2.62 2.2
19 4.59 9.81 500 0.77 0.6
20 4.59 9.81 1000 1.32 1.0
21 4.59 9.81 1500 2.21 2.06
22 4.59 19.6 500 1.52 1.34
23 4.59 19.6 1000 2.51 2.40
24 4.59 19.6 1500 3.46 3.2
25 4.59 39.2 500 1.33 1.10
26 4.59 39.2 1000 2.33 2.0
27 4.59 39.2 1500 3.96 3.3
Table 4
ANOVA for wear results (SiCp)
Source of variances ss Df Variance Test F F p
a
(%)
D 10.91 2 5.455 230.17 5.27
b
57.57
L 4.64 2 2.32 97.89 5.27
b
24.34
S 1.33 2 0.665 28.06 5.27
b
6.8
SXL 0.5 4 0.125 5.27 5.27
b
2.15
SXD 0.34 4 0.085 3.59 2.64
c
1.3
LXD 0.32 4 0.08 3.38 2.64
c
1.2
Pooled error 0.83 35 0.0237 6.64
Total 18.87 53 100
ss, sum of squares; Df, degree of freedom.
a
Percentage of contribution.
b
99% condence level.
c
95% condence level.
Table 5
ANOVA for wear results (SiCpGr)
Source of variances ss Df Variance Test F F p
a
(%)
D 9.38 2 4.69 293.13 5.27
b
57.24
L 3.72 2 1.86 116.25 5.27
b
22.58
S 1.61 2 0.805 50.31 5.27
b
9.66
SXL 0.38 4 0.095 5.94 5.27
b
1.94
SXD 0.34 4 0.085 5.31 5.27
b
1.69
LXD 0.32 4 0.08 5.00 3.95
c
1.57
Pooled error 0.58 35 0.016 5.32
Total 53 100
ss, sum of squares; Df, degree of freedom.
a
Percentage of contribution.
b
99% condence level.
c
95% condence level.
1396 S. Basavarajappa et al. / Materials and Design 28 (2007) 13931398
ll the valley of the material both in pin and the counter
face during the course of action and there is a possibility
of fracturing a few asperities on both the surfaces leading
to very ne debris.
The stress on the surface of the SiCpGr composite pin
is almost uniform and the contact between them is intact,
such that more surface area is in contact. The wear resis-
tance of the graphitic composite is more than that of Al/
SiCp composite. As the sliding distance increases the wear
volume loss increases which can be attributed to the
ploughing ability of the fractured particles between the
pin and the counter face will not decrease with increasing
the sliding distance [34,35]. The dry sliding wear volume
loss increases with increasing load. The SiC particles are
very strong in compression than the tension. This inu-
ences the penetration ability of the fractured particles
between the pin and the counter face. So the removal of
material from the surface of the pin increases with increase
in load [21]. The decreasing trend of the wear rate when
sliding speed is increased is due to the formation of protec-
tive mechanically mixed layer (MML) between the pin and
the counter face [3335]. In Al/SiCpGr composites, the
variation of inuence of factors on the wear volume loss
follows the same trend as that of the Al/SiCp composite.
Along with the protecting layer of MML forms between
the sliding counterparts, graphite also smears and reduces
overall wear volume loss of the composite at all tested
range of parameters.
5. Conclusions
Taguchis robust design method can be used to analyze
the dry sliding wear problem of the metal matrix compos-
ites as described in the paper. The following generalized
conclusions can be drawn from the work.
(A) The incorporation of graphite particles in the alumin-
ium matrix as a secondary reinforcement increases
the wear resistance of the material. The smearing of
the graphite and formation of protecting layer
between the pin and the counter face enables in
reducing the wear volume loss.
(B) Sliding distance is the wear factor that has the highest
physical as well as statistical inuence on the wear of
both composites. SiCp composite present a contribu-
tion of sliding distance (57.57%), load (24.34%), and
sliding speed (6.8%). SiCpGr reinforced composites
present a contribution of sliding distance (57.24%),
the load (22.58%) and sliding speed (9.66%). The
interactions between the wear parameters have statis-
tical signicance but do not have any physical
signicance.
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