International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015
ISSN: 2395-3470
INVESTIGATION OF WEAR BEHAVIOUR OF Al 6061 ALLOY
REINFORCED WITH SiC, Al 2 O 3 AND E GLASS FIBER
R.Saravanan1, K.Vinod2, T.Tamilarasan3
1 Assistant Professor, Kalaignar Karunanidhi Institute of Technology, Coimbatore
2
P
Assistant Professor, Kalaignar Karunanidhi Institute of Technology, Coimbatore
P
3
P Assistant Professor, Kalaignar Karunanidhi Institute of Technology, Coimbatore
P
Abstract
Aluminium 6061 has been used as matrix material
for its excellent mechanical properties coupled with
good formability. Numerous technological challenges
present in casting techniques for obtaining a proper
distribution of reinforcement in the matrix. In this
work Al 6061 alloy act as a matrix and Al 2 O 3 , SiC, E
R R
glass fiber are used as reinforcement. Composites are
fabricated by liquid metallurgy technique (stir casting)
for decreasing the castings fault and to improve the
proper mixing of reinforcement and matrix. Al 6061
alloy is melted at 680 C and then preheated
reinforcements are added to maintaining stirrer speed
around 180 RPM. The smallest amount of
magnesium is added for enhancing usability and then
molten metal is transferred into the mold cavity for
machining composite as per the ASTM standards to
conduct a tribological test in Pin on Disc apparatus.
The Sliding wear tests are conducted at various loads,
Speeds, Sliding distances. Experimental results tells
the minimum wear is found in 10% wt of Al 2 O 3 , 6%
wt of SiC and 4%wt of E glass fiber compared with
Al 6061 alloy.
Keywords: Al 6061, Al 2 O 3 , SiC, E glass fiber, Stir
R R R R
casting, Pin on Disc. liquid metallurgy technique,
preheated reinforcements, Pin on Disc apparatus.
1.Introduction
Aluminium based metal matrix composites have
evoked a keen interest in recent times for potential
applications in marines, aerospace and automotive
industries owing to their superior strength to weight
ratio, good wear and corrosion resistance. Composite
materials are having their desirable properties, which
include high specific stiffness, low density,
controlled co efficient of thermal expansion, high
specific strength, and superior dimensional stability
at elevated temperatures. As the dispersed phase is
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R R R R
P P P P P P
compared to matrix phase it is stronger. So it is called
as reinforcement phase. In this work the various
aspects of the wear behavior of MMCs have been
investigated. Metal Matrix Composites (MMCs) have
resistant with the ceramic particulates and tender to
the significant performance advantages over pure
R R metals and alloys. MMCs are adapt with the best
properties of the two components, such as ductility
and toughness of the matrix. Generally aluminium
alloys are having low density and good adaptability,
good corrosion resistance and high thermal and
electrical conductivity. The objective of the present
study is to investigate the wear behaviour of al 6061
reinforced with Al 2 O 3 , SiC and E glass fiber.
R R R R
2. Literature survey
Prashant Sharma, et.al.[1] have studied the properties
of hybrid metal matrix composites containing
Al,SiC,E glass fiber. His experimental results, says
when increasing the reinforcement compositions the
tensile, hardness are slightly increased. Satyappa
basavarajappa, et.al .[2] have studied the Dry Sliding
R R R R
Wear Behaviour of Hybrid Metal Matrix
Composites.The experiment results, says the wear
rate has been increased with the increasing load and
decreased with increasing speed. Al-qutub, et.al [3]
has studied the Wear properties of 6061 aluminum
alloy composite. This experiment results, says
depending on the load, the wear resistance increased
by the reinforcement and also, the transition load
from mild to sever wear, was increased due to the
addition of the reinforcement. S. Venkat Prasat, et.al.
[4] have investigated the Parameters on the Dry
Sliding Wear Behaviour of Aluminium/Fly
ash/Graphite Hybrid Metal Matrix Composites. From
his investigation results shows a at high sliding
speeds, mechanically mixed layer (mml) and a
lubricating film of graphite were formed between the
composite pin and the steel counter face and they
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 International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015
ISSN: 2395-3470
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reduced the chance of direct metallic contact, thereby small diameters owing to the poor wet ability
lowered the wear rate. Ozben et.al [5] investigated between the matrix and reinforcement.
about the Machinability of MMC and observed 4. Experimental setup
MMC was very different from traditional materials
because of abrasive reinforcement element. This was 4.1. Specimen preparation
due to abrasive element causes more wear on cutting The MMCs were prepared by using cast aluminium
tools. Flank wear of cutting tool are also increased alloy Al 6061 as matrix and Al 2 O 3 , SiC, Eglass fiber
R R R R

with increase in reinforcement ratio. WANG et.al [6] as reinforced materials. In the hybrid MMCs the
investigated the wear performance of Hybrid metal reinforcement materials were used on different
matrix composites using Aluminium oxide (Al 2 O 3 ) R R R R proportions. Table 1 shows the percentage
fibers and Silicon carbide particles as reinforcements composition of the materials. The ratios are randomly
with aluminium cast alloy A536 as matrix and two selected to the field of casting process.
different orientations of fibers, PR-orientation and N-
orientation and three different ratios of
reinforcements.. They observed that the wear
resistance of the specimens with the N-orientation of
the fibers is better than that with the PR-orientation
for all the three hybrid ratios. The coefficient of
friction decreases when the temperature increases.
Furthermore, although the hybrid ratio has little
effect on the coefficient of friction, the fiber
orientation had a greater effect on this. SURESH et.al
[7] investigated the wear behaviour of Al6061MMCs
Fig 1 Al 6061 alloy Composite with 10%,20%,30%
and its relation with Processing & microstructure.
compositions
They concluded the wear rate and coefficient of
friction decreased linearly with increasing weight Table 1 composition of composite materials
percentage of Al 2 O 3 . The wear rate increase as the Al 6061(%) Al203(%) Eglass
SiC(%)
R R R R

sliding speed increases. The best results of minimum fiber(%)

wear have been obtained at 8% weight fraction of
90 5 3 2
Al 2 O 3 . Hariharan et.al [8] observed that the wear
R R R R

resistance of the composite is increased as the 80 10 6 4

percentage of the TiB 2 increases. And also the
R R

increased volume fraction of the TiB 2 particles

R R 70 15 9 6
contributed to increase the strength of composites.
R.L.Deius et.al [9] says the adhesive wear of Al-Si
4.2. Wear test machine
alloy and aluminium composites containing
The wear characteristics of casting Al alloy is tested
discontinues reinforcement phases, such as the role
using pin on disk apparatus. The pin specimen is held
of reinforcement phase encountered by the material.
strongly beside the rotating steel counter disk with
the help of an applied load.
3. Preparation of Al alloy
Generally The Al alloy is produced by various
4.3. Matrix material
methods such as Stir casting, powder metallurgy,
In this investigation 6061 aluminium alloy is used as
squeeze casting process. Here, the stir casting process
a matrix material for preparing the composites.
is mostly used and most adaptable. And also the
Table 2 shows the rate of chemical compositions of
additional benefit of this process is the near net shape
Al 6061 alloy.
formation of the composites by conventional
Table 2 chemical composition
boundary process. Stir casting method is low cost and Element Mg Si Fe Cu Cr Mn Al
easy to put the operation. The basic process is to put
into the second phase of the melt via stirring. Weight % 1.0 0.8 0.7 0.3 0.2 0.15 Remainder
Additionally it is difficult to allocate particles with

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 International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015
5. Experimental Procedure
5.1.Stir Casting Process
Fig 2 Stir casting machine
The matrix alloy was reinforced with 10% wt of
Al 2 O 3 , 6% wt of SiC and 4%wt of E glass fiber
R R R R
compared with Al 6061 alloy by stir casting process.
The production process of matrix alloy and
composites is as follows: Al 6061 alloy is melted at
680 C and then preheated reinforcements are added
to maintaining stirrer speed around 180 RPM. The
smallest amount of magnesium is added for
enhancing usability and then molten metal is
transferred into the mold cavity for machining.
5.2. Wear Test Machine
The wear characteristics of casting Al alloy is tested
using pin on disk apparatus. The pin specimen is held
strongly beside the rotating steel counter disk with
the help of an applied load. The pin Specimen is
pressed against the disk at a specific load usually by
means of an arm or level and attached weights. The
amount of wear is determined measuring appropriate
linear dimensions of both specimens before and after
test, or by weighing both specimens before and after
test.
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ISSN: 2395-3470
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5.2.1Pin On Disc Apparatus Test
Fig 3 Wear test pin on disc machine
A pin-on-disc machine was used to investigate the
dry sliding wear behavior of the aluminum alloy
6061 and Al 2 0 3 , SiC, E glass fiber composites as per
R R R R
ASTM standards. That the Sliding wear tests are
conducted at various loads, Speeds, Sliding distances.
It is noted that three samples were tested for each
conditions in the analysis.
The wear rate was determined using weight loss
method. The wear of the composite was studied as a
function of the applied load. In the wear test the pin
(specimen) was pushed next to the counterpart
rotating against EN 31 steel disc with hardness 56-58
HRC by applying the load. An around strain gauged
friction-detecting arm holds and loads the pin
specimen vertically into a rotating hardened steel
disc. After running throughout the sliding distance of
1884 m for 7 min 57 seconds, the specimen were
removed, cleaned with acetone, dried and weighed to
find the weight loss due to wear. The difference in
the weight measured before and after the test gives
the wear of the specimen. The wear was calculated
using weight loss method.
6. Results & Discussion
6.1. Sem micrographs of the mmcs:
The Scanning electron microscope images of the Cast
Al6061 alloy with three different compositions are
shown in figure 3a,b&c.The microscope clearly
indicates the Wear portions of the material.
 International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015
ISSN: 2395-3470
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6.2.Calculation of Wear rate

Table 3 Parameters of calculating wear rate

LOAD SPEED DISTANCE

10 2 1000

20 3 1750

30 4 2500

Table 4 variation in wear rate for Al 6061 composite

alloy
Fig 4a) SEM micrographs Al6061 10%
composition.
S.NO COMPOSITION TRIAL INITIAL FINAL WEIGHT WEAR
WEIGHT WEIGHT LOSS RATE

(g) (g) (g) (mm3/km)

P P

Al 6061 alloy
1
composite 6.6 6.4 0.2 0.0002
I
with 10%
reinforcement
II 6.4 6.1 0.3 0.0003

Al 6061 alloy
2
composite 5.3 5 0.3 0.0003
Fig 4b) SEM micrographs Al6061 20% I
with 20%
composition.
reinforcement
II 5 4.6 0.4 0.0004

Al 6061 alloy
3
composite 3.8 3.4 0.4 0.0004
I
with 30%
reinforcement

II 3.4 3.1 0.3 0.0003

Fig 4c) SEM micrographs Al6061 30%
composition.
The above table shows the variation of wear rate with
applied load for Al 6061 alloy composites. It can be
observed from the figure that as the applied load
increases the wear rate also increases. At the initial
phase, little change in wear rate was observed for
trail 1 and 2 as the applied load increases more
change in the wear was observed. The wear of the Al

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 International Journal of Scientific Engineering and Applied Science (IJSEAS) - Volume-1, Issue-5, August 2015
ISSN: 2395-3470
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6061 alloy composite with 10% reinforcement is less tribology conference , ISSN 1221 4590
than that of other compositions for all applied load. September 2013.

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