Beruflich Dokumente
Kultur Dokumente
DOI 10.1007/s00170-012-4178-0
ORIGINAL ARTICLE
Received: 24 November 2011 / Accepted: 17 April 2012 / Published online: 8 May 2012
# Springer-Verlag London Limited 2012
1 Introduction
The A413 AlSi alloy with reinforced intermetallic particulates has attracted much attention in recent times due its
H. R. Manohara
SJM Institute of Technology,
Chitradurga 577501, India
T. M. Chandrashekharaiah
Kalpatru Institute of Technology,
Tipatur 572202, India
K. Venkateswarlu (*)
CSIR-National Aerospace Laboratories,
Bangalore 560017, India
e-mail: karodi2002@yahoo.co.in
S. A. Kori
Department of Mechanical Engineering,
Basaveshwar Engineering College,
Bagalkot 587102, India
Present Address:
S. A. Kori
Visvesvaraya Technological University,
Belgaum 590018, India
396
2 Experimental details
2.1 Material
Table 1 shows the weight % of intermetallic additions to A413
alloy. Moreover, Table 2 shows the chemical composition of
A413 alloy with and without intermetallics. All the experimental alloys are prepared by melting and casting route. After
melting the A413 alloy in an electric resistance furnace that
was maintained at 720C, the liquid metal was poured in a
split-type permanent mould of 12.5 mm in diameter and
125 mm in height that was preheated to 100C. After degassing with solid hexachloroethane (C2Cl6), chips that contain
intermetallic particles (Al5 % Al3Ti, Al3 % AlB2, Al3%
TiB2 and Al10 % Al4Sr) were added to the melt for grain
reinforcement purpose. The melt was stirred for 30 s after
adding the grain refiner and poured in to a metallic die after
5 min of holding time. Holding time beyond 5 min in general
is responsible for a fading effect where Si particle size coarsens and the number of nucleating sites available during solidification process decreases.
2.2 Macrostructural analysis
The cast bars of A413 alloys (25 mm diameter and 100 mm
length) with and without intermetallics are sectioned at a
height of 25 mm from the bottom. The freshly cut surface of
the bottom portion was taken for macroscopic studies. One
surface of the sectioned specimen was metallographically
polished. The samples, after polishing, were etched with
Poultons reagent (60 % HNO3 +20 % HCl+5 % HF+
15 % H2O) for obtaining macrostructure. Macroscopic
studies are performed on all the samples before and
after grain reinforcement.
2.3 Microstructural analysis
A specimen of 5 mm in height was cut from the test bar for
macroscopic studies. One surface of the specimen was initially
polished using a belt grinder and then a series of waterproof
emery papers with increasing fineness to remove any scratches
present. Final polishing was carried out on a disc polisher
using alumina powder until a mirror-finish and scratch-free
surface is obtained. Polished samples were cleaned with soap
solution and distilled water. The samples so prepared were
etched using Kellers reagent (2.5 % HNO3 +1.5 % Hcl+1 %
HF+95 % H2O) and observed under light microscopy.
2.4 High temperature wear test
The wear tests were carried out according to ASTM G99-05
standard. The tests were conducted on a pin-on-disc (TR-20PHM 400 Ducom, Bangalore) test machine with a pin heating device and a data acquisition system. The wear specimen (10 mm diameter and 40 mm length) was held inside a
collet and clamped into the taper hole. Surrounding the
Alloy nos.
A1
A2
A3
A4
A5
A6
A413
A413+0.27 % (Al5 % Al3Ti)
A413+0.6 % (Al3 % AlB2 )
A413+0.55 % (Al3 % TiB2 )
A413+0.3 % (Al10 % Al4Sr)
A413+0.55 % (Al3 % TiB2 )+0.3 % (Al10 % Al4Sr)
Alloy composition
A413
Al5 % Al3Ti
Al3 % AlB2
Al3 % TiB2
Al10 % Al4Sr
397
Composition (wt.%)
Si
Cu
Mg
Fe
Mn
Zn
Pb
Sn
Sr
Ti
Al
12.5
0.15
0.15
0.15
0.01
0.1
0.1
0.6
0.2
0.16
0.16
0.16
0.5
0.1
0.1
10
0.2
5.02
2.83
2.28
Bal
Bal
Bal
Bal
Bal
UTS (MPa)
% elongation
VHN
182
199
204
210
211
213
3.74
4.53
5.28
6.52
6.55
7.44
40.11
48.80
49.52
51.02
55.37
55.60
398
Fig. 1 ac Photomacrographs
of A413 alloy a). without
addition of reinforcement, b).
with 0.55wt% of Al-3%TiB2
and, c). With combined addition
of (0.55wt of Al-3% TiB2
+0.3wt% of Al-10%Al4Sr)
Fig. 2 af Photomicrographs
of A413 alloy a) without
addition of reinforced
intermetallic alloys b) With
0.275wt% of AI-5%AI3Ti c)
0.60wt% of AI-3%AIB2 d)
0.55% of AI-3%TiB2 e) with
0.3wt of AI_10%aSr & f) with
combine addition of 0.55wt%
of AI-3% TiB2 +0.3wt% of AI10%AI4Sr
properties such as ultimate tensile stress, percentage elongation and microhardness of the alloy can be achieved with
the addition of reinforced intermetallic alloys. It is also clear
that the combined addition of reinforced alloys to A413 Al
Si alloy has resulted in maximum improvement of mechanical properties as compared to the individual addition of
reinforced alloys.
The influence of temperature on wear rate of A413 alloy
is presented in Fig. 3. The wear rate for both the A413 alloy
and composites is similar. It was observed that the wear rate
was decreased for alloy and its composites with increase in
temperature. However, predominantly, the wear rates of
composites are lower than that of alloy. The tests can perform well up to 250C, but the A413 alloy can withstand up
to 200C. The gross damage of a specimen during the test
was observed under a sliding distance of 1,669.46 m at 200
C for A413 alloy. The contact surfaces at high temperature
operating conditions are susceptible to oxidation by reacting
with the environment. It was observed that an oxidation
effect also happened even at room temperature. The wear
rate of A413 base alloy and with intermetallics was reduced
when the operating temperature was increased. This is due
to the formation of a glaze layer, which offers protection [4,
5, 7]. During high temperature sliding, tearing of oxide
layers takes place because of thermal stresses and compaction due to applied pressure resulting in agglomerated clusters of oxide wear debris. Eventually, due to temperature and
applied pressure, sintering of fine wear debris occurs. The
rate of sintering was increased with an increase in temperature, which results in the formation of solid smooth hard
surfaces termed as glaze [7, 911]. The glaze layers protect
the sliding surfaces for a longer time from developed forces
and hence the wear rate is reduced. The failure of glaze later
399
400
Fig. 4 af Effect of
temperature on the coefficient
of friction
401
4 Conclusions
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Research highlights
1. Wear rate of A413 and its composites decreases with increase in
the temperature
2. Al-Si with Al3Ti, TiB2, AlB2, Al4Sr intermetallics showed good
sliding wear results
3. oxide film formation is more rapid at high operating temperatures
4. Oxide layers prevent the direct metal to metal contact of surfaces
during sliding
Statement of originality
We, authors of the present manuscript fully certify that the work is
carried out in our laboratory. All experiments on sliding wear test have
been conducted using our existing tribological facilities. The work is
original and not copied from others. We are fully responsible all the
items mentioned in the manuscript.