Effect of surface area on the wear properties of Al-based automotive alloy and the role of Si at eutectic level

Authors

  • Mohammad Salim Kaiser International University of Business Agriculture and Technology, Innovation Centre, Dhaka-1230, Bangladesh
  • Al-Kabir Hossain Bangladesh University of Engineering and Technology, Department of Mechanical Engineering, Dhaka-1000, Bangladesh

DOI:

https://doi.org/10.14311/AP.2024.64.0368

Keywords:

Al-alloy, contract area, wear, friction, worn surfaces, micrographs

Abstract

The efficiency of an engine material is closely correlated with its surface area. In order to investigate wear properties, effect of surface contact area as well as silicon addition at the eutectic level of Al-Cu-Mg alloy has been studied. This test is performed under room atmosphere and dry sliding conditions using a standard pin-on-disk apparatus. Weight reduction method is adopted to measure the wear rate in microns to get more accurate results. A load varying from of 5 to 50 N and a constant sliding speed of 0.77 ms−1 are maintained throughout the test. The test results show that a lower contact surface area has a negative impact on the wear properties having higher wear rate, while the coefficient of friction of the alloy and Si addition into the alloy improve the properties to some extent. Reduction of the contact surface area increases the unit pressure and decreased material volume causes softening of the alloy matrix, resulting in a higher wear rate and coefficient of friction. The Si addition offers such an improvement mostly for an increase in strength via the Si-rich intermetallic formation. A microstructural study confirms a lower abrasive wear with a minor plastic deformation on the worn surfaces of Si added alloy and wear with higher contact surface. The Si-added alloys contain the fine and strong Si-rich intermetallic, which are responsible for such a smooth worn surface.

Downloads

Download data is not yet available.

References

P. Zhou, D. Wang, H. Nagaumi, et al. Microstructural evolution and mechanical properties of Al-Si-Mg-Cu cast alloys with different Cu contents. Metals 13(1):98, 2023. https://doi.org/10.3390/met13010098

M. Javidani, D. Larouche. Application of cast Al-Si alloys in internal combustion engine components. International Materials Reviews 59(3):132–158, 2014. https://doi.org/10.1179/1743280413Y.0000000027

H. Ye. An overview of the development of Al-Si-alloy based material for engine applications. Journal of Materials Engineering and Performance 12(3):288–297, 2003. https://doi.org/10.1361/105994903770343132

A. Mostafa, N. Alshabatat. Microstructural, mechanical and wear properties of Al-1.3%Si alloy as compared to hypo/hyper-eutectic compositions in Al-Si alloy system. Crystals 12(5):719, 2022. https://doi.org/10.3390/cryst12050719

M. S. Kaiser. Effects of solution treatment on wear behaviour of Al-12Si-1Mg piston alloy containing trace Zr. MAYFEB Journal of Materials Science 1:27–38, 2016.

Z. Yang, X. He, B. Li, et al. Influence of Si, Cu, B, and trace alloying elements on the conductivity of the Al-Si-Cu alloy. Materials 15(2):426, 2022. https://doi.org/10.3390/ma15020426

H. Zhang, B. Chen, J. Hao, et al. Effects of Cu/Er on tensile properties of cast Al-Si alloy at low temperature. Materials 16(3):902, 2023. https://doi.org/10.3390/ma16030902

M. N. Ervina Efzan, H. J. Kong, C. K. Kok. Review: Effect of alloying element on Al-Si alloys. In Materials, Industrial, and Manufacturing Engineering Research Advances 1.1, vol. 845 of Advanced Materials Research, pp. 355–359. Trans Tech Publications Ltd, 2014. https://doi.org/10.4028/www.scientific.net/AMR. 845.355

A. A. Khan, M. R. Shoummo, M. S. Kaiser. Surface quality of Fe, Ni and Cr added hyper-eutectic Al-Si automotive alloys under up-milling and down-milling operation. Journal of Mechanical Engineering Science and Technology (JMEST) 6(1):9–22, 2022. https://doi.org/10.17977/um016v6i12022p009

S.-S. Ahn, S. Pathan, J.-M. Koo, et al. Enhancement of the mechanical properties in Al-Si-Cu-Fe-Mg alloys with various processing parameters. Materials 11(11):2150, 2018. https://doi.org/10.3390/ma11112150

M. Zhang, Y. Tian, X. Zheng, et al. Research progress on multi-component alloying and heat treatment of high strength and toughness Al-Si-Cu-Mg cast aluminum alloys. Materials 16(3):1065, 2023. https://doi.org/10.3390/ma16031065

M. S. Kaiser, A. A. Khan. Role of silicon on the tribological performance of Al-based automotive alloys and the effect of used motor oil. Tribologia – Finnish Journal of Tribology 39(3–4):12–20, 2022. https://doi.org/10.30678/fjt.120669

N. Kang, P. Coddet, C. Chen, et al. Microstructure and wear behavior of in-situ hypereutectic Al-high Si alloys produced by selective laser melting. Materials & Design 99:120–126, 2016. https://doi.org/10.1016/j.matdes.2016.03.053

M. Al Nur, A. A. Khan, S. Dev Sharma, M. S. Kaiser. Electrochemical corrosion performance of Si-doped Al-based automotive alloy in 0.1M NaCl solution: Original scientific paper. Journal of Electrochemical Science and Engineering 12(3):565–576, 2022. https://doi.org/10.5599/jese.1373

S. J. S. Chelladurai, S. S. Kumar, N. Venugopal, et al. A review on mechanical properties and wear behaviour of aluminium based metal matrix composites. In Materials Today: Proceedings, vol. 37, pp. 908–916. 2021. https://doi.org/10.1016/j.matpr.2020.06.053

G. Li, S. Hao, W. Gao, Z. Lu. The effect of applied load and rotation speed on wear characteristics of Al-Cu-Li alloy. Journal of Materials Engineering and Performance 31(7):5875–5885, 2022. https://doi.org/10.1007/s11665-022-06613-x

G. E. Totten (ed.). ASM handbook, Volume 18: Friction, lubrication and wear technology. ASM International, Materials Park, USA, 1992.

M. A. Islam, Z. N. Farhat. Effect of porosity on dry sliding wear of Al-Si alloys. Tribology International 44(4):498–504, 2011. https://doi.org/10.1016/j.triboint.2010.12.007

V. Romanova, R. Balokhonov, O. Zinovieva, et al. The relationship between mesoscale deformation-induced surface roughness, in-plane plastic strain and texture sharpness in an aluminum alloy. Engineering Failure Analysis 137:106377, 2022. https://doi.org/10.1016/j.engfailanal.2022.106377

I. V. Lytvynenko, P. O. Maruschak, S. A. Lupenko, P. V. Popovych. Modeling of the ordered surface topography of statically deformed aluminum alloy. Materials Science 52(1):113–122, 2016. https://doi.org/10.1007/s11003-016-9933-1

S. Toschi. Optimization of A354 Al-Si-Cu-Mg alloy heat treatment: Effect on microstructure, hardness, and tensile properties of peak aged and overaged alloy. Metals 8(11):961, 2018. https://doi.org/10.3390/met8110961

M. S. Kaiser, A. S. W. Kurny. Effect of scandium on the grain refining and ageing behaviour of cast Al-Si-Mg alloy. Iranian Journal of Materials Science & Engineering 8(4):1–8, 2011.

J. R. Davis (ed.). Metals handbook desk edition, 2nd edition. ASM International, Ohio, USA, 1998. ISBN 978-0-87170-654-6.

M. M. Khan, A. Dey, M. I. Hajam. Experimental investigation and optimization of dry sliding wear test parameters of aluminum based composites. Silicon 14(8):4009–4026, 2022. https://doi.org/10.1007/s12633-021-01158-5

A. Mostafa, N. Alshabatat. Microstructural, mechanical and wear properties of Al-1.3%Si alloy as compared to hypo/hyper-eutectic compositions in Al-Si alloy system. Crystals 12(5):719, 2022. https://doi.org/10.3390/cryst12050719

I. J. Polmear. Light alloys: Metallurgy of the light metals. Arnold, London, UK, 3rd edn., 1995.

S. Nikzad Khangholi, M. Javidani, A. Maltais, X.-G. Chen. Investigation on electrical conductivity and hardness of 6xxx aluminum conductor alloys with different Si levels. In MATEC Web of Conferences, vol. 326, p. 08002. 2020. https://doi.org/10.1051/matecconf/202032608002

A. K. Gupta, D. J. Lloyd, S. A. Court. Precipitation hardening in Al-Mg-Si alloys with and without excess Si. Materials Science and Engineering: A 316(1–2):11–17, 2001. https://doi.org/10.1016/S0921-5093(01)01247-3

F.-b. Meng, H.-j. Huang, X.-g. Yuan, et al. Effect of Si addition on microstructure and mechanical properties of Al-Mg-Si-Zn alloy. China Foundry 17(1):15–20, 2020. https://doi.org/10.1007/s41230-020-9102-x

M. S. Prabhudev, V. Auradi, K. Venkateswarlu, et al. Influence of Cu addition on dry sliding wear behaviour of A356 alloy. In Procedia Engineering, vol. 97, pp. 1361–1367. 2014. https://doi.org/10.1016/j.proeng.2014.12.417

Y. Yang, K. Yu, Y. Li, et al. Evolution of nickel-rich phases in Al-Si-Cu-Ni-Mg piston alloys with different Cu additions. Materials & Design 33:220–225, 2012. https://doi.org/10.1016/j.matdes.2011.06.058

J. F. Archard. Contact and rubbing of flat surfaces. Journal of Applied Physics 24(8):981–988, 1953. https://doi.org/10.1063/1.1721448

M. S. Kaiser, M. A. Matin, K. M. Shorowordi. Role of magnesium and minor zirconium on the wear behavior of 5XXX series aluminum alloys under different environments. Journal of Mechanical and Energy Engineering 4(3):209–220, 2020. https://doi.org/10.30464/jmee.2020.4.3.209

H.-J. Kim, A. Emge, S. Karthikeyan, D. A. Rigney. Effects of tribooxidation on sliding behavior of aluminum. Wear 259(1–6):501–505, 2005. https://doi.org/10.1016/j.wear.2005.01.043

R. Escalera-Lozan, M. I. Pech-Canul, M. A. Pech-Canul, et al. The role of Mg2Si in the corrosion behavior of Al-Si-Mg alloys for pressureless infiltration. The Open Corrosion Journal 3:73–79, 2010. https://doi.org/10.2174/1876503301003010073

K. N. D. Malleswararao, I. N. N. Kumar, B. Nagesh. Friction and wear properties of rapid solidified H-Al-17Si alloys processed by UV assisted stir – squeeze casting with DLC-star (CrN + a-c:H) coating under HFRR. Tribology in Industry 42(4):529–546, 2020. https://doi.org/10.24874/ti.870.04.20.09

S. M. Aouadi, H. Gao, A. Martini, et al. Lubricious oxide coatings for extreme temperature applications: A review. Surface and Coatings Technology 257:266–277, 2014. https://doi.org/10.1016/j.surfcoat.2014.05.064

A. J. W. Moore, W. J. McG. Tegart. Relation between friction and hardness. Proceedings of the Royal Society of London Series A Mathematical and Physical Sciences 212(1111):452–458, 1952. https://doi.org/10.1098/rspa.1952.0234

S. A. Kori, T. M. Chandrashekharaiah. Studies on the dry sliding wear behaviour of hypoeutectic and eutectic Al-Si alloys. Wear 263(1–6):745–755, 2007. https://doi.org/10.1016/j.wear.2006.11.026

M. S. Kaiser, M. R. Qadir, S. Dutta. Electrochemical corrosion performance of commercially used aluminium engine block and piston in 0.1M NaCl. Journal of Mechanical Engineering 45(1):48–52, 2015. https://doi.org/10.3329/jme.v45i1.24384

X. Li, H. Yan, Z.-W. Wang, et al. Effect of heat treatment on the microstructure and mechanical properties of a composite made of Al-Si-Cu-Mg aluminum alloy reinforced with SiC particles. Metals 9(11):1205, 2019. https://doi.org/10.3390/met9111205

B. Sirahbizu Yigezu, M. Mahapatra, P. Jha. Influence of reinforcement type on microstructure, hardness, and tensile properties of an aluminum alloy metal matrix composite. Journal of Minerals and Materials Characterization and Engineering 1(4):124–130, 2013. https://doi.org/10.4236/jmmce.2013.14022

S. Lynch. A review of underlying reasons for intergranular cracking for a variety of failure modes and materials and examples of case histories. Engineering Failure Analysis 100:329–350, 2019. https://doi.org/10.1016/j.engfailanal.2019.02.027

R. Rashid, S. H. Masood, D. Ruan, et al. Effect of energy per layer on the anisotropy of selective laser melted AlSi12 aluminium alloy. Additive Manufacturing 22:426–439, 2018. https://doi.org/10.1016/j.addma.2018.05.040

D. A. Lados, D. Apelian, J. F. Major. Fatigue crack growth mechanisms at the microstructure scale in Al-Si-Mg cast alloys: Mechanisms in regions II and III. Metallurgical and Materials Transactions A 37(8):2405–2418, 2006. https://doi.org/10.1007/BF02586215

Downloads

Published

2024-09-08

Issue

Section

Articles

How to Cite

Kaiser, M. S., & Hossain, A.-K. (2024). Effect of surface area on the wear properties of Al-based automotive alloy and the role of Si at eutectic level. Acta Polytechnica, 64(4), 368-378. https://doi.org/10.14311/AP.2024.64.0368