Composites: Part B 56 (2014) 464–471

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Composites: Part B
journal homepage: www.elsevier.com/locate/compositesb

Study on mechanical and wear properties of Al 7075/Al2O3/graphite

hybrid composites
A. Baradeswaran a,b,⇑, A. Elaya Perumal a
a
Department of Mechanical Engineering, College of Engineering Guindy, Anna University, Chennai, India
b
Department of Mechanical Engineering, Madha Engineering College, Chennai, India-600069

a r t i c l e i n f o a b s t r a c t

Article history: This work investigated the influence of graphite on the wear behavior of Al 7075/Al2O3/5 wt.% graphite
Received 31 December 2012 hybrid composite. The investigation reveals the effectiveness of incorporation of graphite in the compos-
Received in revised form 22 February 2013 ite for gaining wear reduction. The Al 7075 (aluminium alloy 7075) reinforced with Al2O3–graphite were
Accepted 12 August 2013
investigated. The composites were fabricated using liquid metallurgy route. Ceramic particles along with
Available online 20 August 2013
solid lubricating materials were incorporated into aluminium alloy matrix to accomplish reduction in
both wear resistance and coefficient of friction. The Al 7075/Al2O3/graphite hybrid composite was pre-
Keywords:
pared with 5 wt.% graphite particles addition and 2, 4, 6 and 8 wt.% of Al2O3. The hardness, tensile
A. Metal-matrix composites (MMCs)
A. Particle-reinforcement
strength, flexural strength and compression strength of the Al 7075–Al2O3–graphite hybrid composites
B. Wear are found to be increased by increased weight percentage of ceramic phase. The wear properties of the
E. Casting hybrid composites containing graphite exhibited the superior wear-resistance properties.
Ó 2013 Elsevier Ltd. All rights reserved.

1. Introduction particulate reinforced aluminium alloy composites for tribological

Wear is one of the important phenomena that takes place at a
materials interface metal matrix composites (MMCs) with rein-
forcement of hard particles that offer superior performance and
wear resistance [1]. Aluminium based MMCs have been a very
valuable addition to the field of newer materials for high perfor-
mance tribological applications. Aluminium based composites are
being increasingly used in automobile, aerospace, marine and min-
eral processing industries owing to their improved specific
strength, good wear resistance, higher thermal conductivity and
lower coefficient of thermal expansion. The widely used reinforced
materials for this composite are silicon carbide (SiC), aluminium
oxide (Al2O3) and graphite in the form of particles or whiskers
[2–6]. Aluminium matrix composites normally fabricated by liquid
casting technique or powder metallurgy route [7–10]. In the liquid
casting technique, the particulates are mechanically well distrib-
uted over the liquid metal before casting and solidification [11–
14]. These methods are typically cost effective [15,10]. Aluminum
based MMCs reinforced with ceramic particles developed better
mechanical properties than unreinforced aluminium alloys
[16,17] and are most widely used for tribological parts due to their
high ratio of strength, stroke density and improved wear resistance
[18,19]. This has been an incentive for increasing attention towards
⇑ Corresponding author. Address: Department of Mechanical Engineering, Madha
Engineering College,Chennai 600 069, India. Tel.: +91 9710363105; fax: +91 44
24780798.
E-mail address: barathme@yahoo.co.in (A. Baradeswaran).
applications [20,21]. Kok and Ozdin [22] investigated the effect of
Al2O3 particle content and size on the wear behavior of Al2O3 par-
ticle reinforced 2024 aluminium alloy composites fabricated by
vortex method. Surappa et al. [23] have studied the influence of
5 vol.% Al2O3 particles addition on the wear resistance of hyper
eutectic Al–Si alloys. Earlier Straffelini et al. [24] have reported
on the influence of the matrix hardness on dry sliding wear behav-
ior of Al 6061/Al2O3 composites, Yu et al. [25] have studied the ef-
fects of applied load and temperature on the dry sliding behavior of
Al 6061/SiC composites, Liang et al. [26] have identified that the
MMCs containing SiC particles exhibit improved wear resistance.
Reda et al. [27] and Clark et al. [28] have reported that pre-aging
at various retrogation temperatures improves the hardness, tensile
properties and electrical resistivity of Al 7075. Kim et al. [29] con-
cluded that the hardness of aged Al 7075 alloy was increased. Doel
and Bowen [30] have reported the improved tensile strength and
lower ductility of Al 7075 reinforced with SiC particles than that
of unreinforced, Komai et al. [31] have identified superior mechan-
ical properties of Al 7075–SiCW composites.
Generally lubricant is externally added to reduce the wear. This
poses the problem when the materials need the periodic applica-
tions of lubricant particularly to wear parts which are difficult to
access. For such applications self-lubricating materials are pre-
ferred because the solid lubricant contained in them can be auto-
matically released during the wear process to reduce the wear.
Graphite is one of the most widely used solid lubricant materials.
Earlier researchers [32–35] have already focused their investiga-
tion on applications of aluminium graphite composite. There are

1359-8368/$ - see front matter Ó 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.compositesb.2013.08.013
 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471
also earlier reports from some investigators [36,37] who identified
the trend that aluminium graphite composite containing the small
amount of graphite exhibit superior wear properties over the base
alloys. The limitation with the aluminium graphite composite is in
using graphite as a solid lubricant whose introduction results in
the loss of strength of the composite.
It is, therefore, proposed to undertake a study on the effective-
ness of reinforcements mixed with Al 7075. Aluminum with 5 wt.%
of graphite is reinforced with Al2O3 to form a stronger hybrid com-
posite (Al 7075/Al2O3/graphite).
2. Materials and methods
2.1. Chemicals and instruments
Al 7075, graphite and Al2O3 were purchased from Krishmet
India Pvt. Ltd., Chennai. The casting facility was used from Madras
Institute of Technology (MIT), Chrompet, Chennai. The wear and
friction tests were measured using pin on disc apparatus (model:
02), IIT Madras, Chennai, India. The flexural strength was measured
using UTM machine (UTE40). The scanning electron micrographs
(SEMs) were recorded using Hitachi-S3400 scanning electron
microscope (SEM).
2.2. Material fabrication
The chemical compositions of the Al 7075 alloy is given in Table 1.
The Al 7075 containing 5 wt.% graphite composite was reinforced
with 2, 4, 6 and 8 wt.% Al2O3 about an average particulate size of
16 lm were prepared by a stir casting process. About 1.0 kg of Al
7075 alloy is melted in a graphite crucible heated to 850 °C. When
the temperature of the melt is about 30 °C above the pouring tem-
perature preheated stirrer is introduced in the melt. Agitation of
the melt is started and the preheated Al2O3 particulates are intro-
duced in the wt.% of 2, 4, 6 and 8 and followed by the addition of
5 wt.% graphite. The mixture was stirred at 500 rpm for 5 min by
means of a spiral-shaped stirrer coupled to a motor and the temper-
ature was kept persistent at 850 °C. Due to the stirring action, the
melted aluminium alloy was split into droplets owing to the shear
forces brought by the impeller due to the existence of graphite.
The stirring is continued to ensure a proper mixing and slurry. The
slurry of the composites thus prepared was poured into the pre-
heated steel moulds. The composite were given a T6 heat treatment
and the specimens for hardness, tensile strength, compressive
strength, flexural strength and wear test were prepared from these
composites.
2.3. Wear test
A pin on disc test apparatus shown in Fig. 1 was used to inves-
tigate the dry sliding wear behavior of Al 7075/Al2O3/5 wt.% graph-
ite hybrid composites. Pin specimens of 6 mm diameter and
15 mm height for wear test was prepared from the above compos-
ites were machined and polished metallographically.
Table 1
Chemical composition of Al 7075.
Element Symbol Composition % in Al 7075
Zinc Zn 5.4
Copper Cu 1.42
Manganese Mn 0.12
Magnesium Mg 2.42
Ferrite Fe 0.42
Chromium Cr 0.21
Aluminium Al Remaining
465
An OHNS (Oil Hardened Nickel Steel) 55 mm diameter steel disc
of 60HRc was used as the counter surface in the wear test. The test
was conducted with various loads of 20 N, 40 N and 60 N at a slid-
ing speed of 0.6, 0.8 and 1.0 m/s for the constant sliding distance of
2000 m. The test was conducted at room temperature (30 °C) and
relative humidity of 60–65%.
The initial weight of the specimen was measured in an elec-
tronic weighing machine with a least count of 0.0001 g. A strain
gauged friction detecting arm holds and loads the pin specimen
vertically on a rotating hardened steel disc. The frictional traction
encounted by the pin during sliding is measured continuously by
a PC-based data-logging system for analysis. The wear test was
conducted after the initial run in period when the pin specimens
were entirely in contact with the disc surface. In each test after
running the fixed sliding distance the specimen was removed,
cleaned with acetone, dried and weighed to determine the weight
loss due to wear. The wear rates were determined using the weight
loss method.
2.4. Hardness test
The hardness tests were carried out according to ASTM E10-07
standards using Brinell hardness testing machine with a 10 mm
ball indenter and 500 kg load for 30 s. The test was conducted at
room temperature (30 °C) and the measurement of hardness was
taken at five different places on each sample to obtain an average
value of hardness.
2.5. Tensile test
As per the ASTM E08-8 standard, the tensile strength was eval-
uated on the cylindrical rod of casted composites. The 1200 grit
grinding SiC paper was used to polish the test specimens in order
to decrease the machining scratches and the effects of surface de-
fects on the sample. The universal testing machine (UTM-Auto
instrument) loaded with 10 kN load cell was used to conduct the
tensile test. The tensile strength was evaluated at cross head speed
of 2.5 mm/min.
2.6. Compression test
The compression test was performed on these samples with
computerized universal Testing Machine (UTM-Auto instrument))
at room temperature and ultimate compression strength of these
samples was measured as per ASTM E9-09 standards. Since it is a
computerized machine the ultimate compressive strength was re-
corded accurately. The test was conducted at a cross head speed of
1 mm/min.
2.7. Three point bending test
Three point bending test was realistic instead of tensile test
and compression test in investigating of particle reinforced metal
matrix composites. The main reason was aluminium oxide
particulates make the notch effect during testing. Since
machining of Al2O3 reinforced aluminium matrix composites,
surface is a very subtle and special process, structure may be
weakened. Machining was done with high speed diamond
tools.
Three point bending test was performed to reveal the flexural
strength of aluminum with 5 wt.% of graphite composite and
with different percentage additions of aluminium oxide. In
three-point bending test, the maximum bending load was evalu-
ated. This load value was converted into flexural strength (MPa)
value. The three point bending test specimens were shown in
Fig. 2.
466 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471

Fig. 1. Schematic diagram of pin on disc apparatus.

Fig. 2. Three point bending test specimen.

Fig. 3. Brinell hardness of Al 7075/Al2O3F/5 wt.% graphite hybird composites.

The flexural strength formula is given as:

loy characterized to the hard nature of Al2O3 particles. The
r  M  y=I hardness decreases with the addition of graphite particles to the
where r is the flexural stress; M is bending moment; y is distance aluminium alloy [6]. To overcome this, the Al2O3 hard ceramic par-
from the natural axis and I is the moment of inertia. ticle was added and it can act as the obstacles to the movement of
The maximum flexural surface stress occurs in the mid-point of dislocation [24,38,39].
the specimen. The Al2O3 particles in the matrix alloy provide protection to the
Therefore: softer matrix. Thus, limiting the deformation and also resists the
penetration and cutting of slides on the surface of the composites
M  P  L=4 [22].
y  t=2 Hamid Abdulhaqq et al. [69], concluded that addition of hard
ceramic results in significant increase in the bulk hardness of
I  b  t 3 =12
rmax  ð3  P  LÞ=ð2  b  t2 Þ
where P is the load applied by the testing machine; T is thickness of
the specimen; B is breath of the specimen, and L is the span length.

3. Results and discussion

3.1. Effect of reinforcements

The effect of graphite and Al2O3 on the hardness and the tensile
strength of the composite obtained from hardness test and tensile
test are shown in Figs. 3 and 4. The hardness measurements were
carried out on a Brinell hardness testing machine.
From Fig. 3 it is observed that the hardness of the Al 7075/
Al2O3/graphite hybrid composite increases with the addition of
Al2O3. It was higher than that of base alloy. Hardness of all the hy- Fig. 4. Variation of tensile strength with varying content of Al2O3 and 5 wt.%
brid composites was significantly greater than that of the base al- graphite.
 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471
aluminium alloy. The higher hardness values for the hybrid
composites containing 8 wt.% of Al2O3 is due to the presence of
hard Al2O3 particles. This result is a good agreement with the result
of Mahdavi and Akhlaghi [62].
The variation of ultimate tensile strength with varying Al2O3
was shown in Fig. 4. The tensile strength was increased with
increasing Al2O3 content. The graphite addition normally decreases
the strength [62] but with the addition of Al2O3 particles improves
the mechanical properties mainly by stress transference from the
aluminium matrix to the reinforced particles Al2O3. This is because
of orowan mechanism by which a dislocation bypasses impenetra-
ble obstacles where a dislocation bows out considerably to leave a
dislocation loop around a particle [23]. The interaction between
the dislocations and Al2O3 results in an improved in strength.
The ultimate compressive strength increases with increasing
Al2O3 is shown in Fig. 5 and it was noticed that the hybrid compos-
ites are greater than that of base alloy and similar data reported by
Embury [67]. It is known that the mechanical strength decreased
due to the addition of graphite and for improving the mechanical
strength, the Al2O3 hard ceramic particles are added. The ultimate
compressive strength of the hybrid composite was increased with
the addition of Al2O3 and it was improved 10% than that of base al-
loy. This is because of the hybrid composites became tougher with
the increased Al2O3 particles. This was persistent till the matrix can
lodge the particles without distortion and this is good agreement
with the results of Mcdanels [66]. It is known that reinforcement
constituents are one of the important factors controlling the
strength of Al–Al2O3–Gr hybrid composites. Al2O3 particles being
hard and brittle lead to dispersion hardening of matrix. These par-
ticles act as second phase in the matrix and resist the movement of
dislocations and hence harden the composites [65].
The flexural strength of the composites obtained from three-
point bending test is shown in Fig. 6 indicates that the flextural
strength was increased with the addition of Al2O3 with graphite.
In general, addition of graphite to aluminum alloys is known to de-
crease the strength [40–42], hardness [43–46], fracture energy and
ductility of the material [47] but with the addition of Al2O3 to the
matrix increases the flexural strength. The structure and properties
of the reinforcements controls the mechanical properties of the
composites that are reasoned to strong interface that transfers
and distributes the load from the matrix to the reinforcements
exhibiting increased elastic modulus and strength [70]. The brittle-
ness of the Al2O3 particles together with the interface between
graphite and matrix leads to the increase in the flexural strength
of the composites and it was higher than that of the base alloy.
The optimum characteristic is gained by the description given in
the fewer cases about the optimum graphite quantity [48,49]. In
order to strengthen the tribological and mechanical characteristics
Fig. 5. Variation in compression strength with varying Al2O3.
467
Fig. 6. Variation of flexural strength with varying content of Al2O3.
the hard reinforcing particles into the matrix alloy is incorporated.
Nevertheless this may result with rapid counter face along with
deteriorated machinability [50–57]. The hard and solid lubricant
materials can be obtained from the hybrid composites which has
strengthened tribological and mechanical properties been devel-
oped [58–61]. The flexural strength was increased 23% than that
of Al 7075.
3.2. Wear behavior of the composites
The wear behavior of the hybrid composites Al 7075/Al2O3/
graphite is shown in Figs. 7 and 8. The wear rate decreases with
the addition of Al2O3 and reaches a minimum at 2 wt.% Al2O3/
5 wt.% graphite and it is about 36% less than that of the matrix
material Al 7075, whereas the wear rate of the hybrid composite
decreases with increasing sliding speed. At larger sliding distance,
rise of temperature of the sliding surfaces are unavoidable and
heavy deformation at higher sliding distance [71] but dropping of
the wear rate of the hybrid composite relative to the Al 7075 can be
reasoned to the beneficial effect of the graphite addition in reduc-
ing the wear of the composites due to formation of a thin lubricat-
ing graphite film on the tribosurface. The subsequent marginal
increasing trend of these hybrid composites at 8 wt.% Al2O3 over-
shooting the wear rate can be the adverse effect of the hard
Al2O3 particle addition together with the increasing tendency of
crack initiation and propagation at the Al2O3/metal interface. The
wear rate increases with increasing applied load and at all the load
condition; the minimum wear rate was at 2 wt.% Al2O3/5 wt.%
graphite hybrid composites.
The Al2O3 particles act as load bearing elements in the hybrid
composites and also it results in formation of more stable lubricat-
Fig. 7. Wear rate of Al 7075/Al2O3/5 wt.% graphite hybrid composites.
468 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471

Fig. 8. Wear rate of hybrid composites with varying sliding speeds. Fig. 9c. Scanning electron micrograph of worn surface of Al 7075/4 wt.% Al2O3/
5 wt.% graphite.

Fig. 9a. Scanning electron micrograph of worn surface of Al 7075.

Fig. 9d. Scanning electron micrograph of worn surface of Al 7075/6 wt.% Al2O3/
5 wt.% graphite.

Fig. 9b. Scanning electron micrograph of worn surface of Al 7075/2 wt.% Al2O3/
5 wt.% graphite.

ing film on the tribo surface of the hybrid composites. The de-
creased wear rate of hybrid composite with graphite content can
be ascribed to the collective effects of graphite and Al2O3 particles Fig. 9e. Scanning electron micrograph of worn surface of Al 7075/8 wt.% Al2O3/
in formation of a more resistant tribolayer on the contact surface 5 wt.% graphite.
[10,49,56,62]. The graphite tribo film minimize the degree of shear
stress transferred to the sliding material underneath the sliding
contact area which results in less plastic deformation in the sub Oxidation of metallic particle occurs in the working atmosphere
surface region and reduces the wear rate in the hybrid composites. and oxides are formed which spread and form a layer on the pin
 A. Baradeswaran, A. Elaya Perumal / Composites: Part B 56 (2014) 464–471
Fig. 10. EDX spectrum of worn surface of hybrid composite sample.
surface. Once the oxide layers are formed; distortion, spalling and
fracture of the layers take place over the pin mating surface in the
course of sliding. All the oxides are not completely dislodged from
the mating surface, some amounts present between the mating
surfaces offers wear resistance due to the dilution of metallic con-
tact of the surface. But as the load exceeded a certain value a sig-
nificant decrease in wear resistance is observed, so at higher
loads gross damage occurs to the pin material [68].
3.3. Morphological analysis
SEM analysis of the worn surface of hybrid composites is shown
in Figs. 9a–e. An examination of the morphologies of the worn sur-
faces indicates the existence of abrasion and delamination wear
mechanisms in these composites. Fig. 9a shows the worn surface
of the matrix alloy reveals patches of severely damaged regions
and deep abrasion grooves due to heavy plastic deformation [63].
The delamination wear is also noticed in matrix alloy. Fig. 9b
shows the worn surface of the Al 7075/5 wt.% graphite/2 wt.%
Al2O3 hybrid composite. Surface damage in the form of decohesion
and detachments of the material near the contact surface were ob-
served. Cracks and small cavities are also visible on the surface.
Distinct grooves are visible in the sliding direction. The smeared
graphite particles from the worn surface of composites form a thin
rich tribofilm between sliding surfaces, which prevent direct metal
contact. This is clearly indicates that wear rate can be related to the
presence of graphite film layer, which may act as a protective layer.
This film prevents the breaking of hard Al2O3 particles from the pin
surface, which results in less surface damage. Delamination wear
are found in localized regions.
Figs. 9c–e show that the worn surfaces of Al 7075 with 4, 6 and
8 wt.% of Al2O3 and 5 wt.% graphite. Due to increase in Al2O3 parti-
cle on the surface of matrix, the plastic deformation of matrix can
be resisted with the presence of Al2O3 which act as a barrier to the
moment of dislocation which causes the more wear resistance than
base alloy. The mild patches and grooves are noticed.
Fig. 10 shows the EDS analysis of the worn surface after being
wear tested. The main observation is the amount of iron present
in the surface. Iron is transmitted from the wearing counter face
[63] by a mechanism of mechanical alloying which results in the
formation of a MML in the wearing surface. It indicates that the
iron transfer layer inhibits contact between the surfaces, hence
469
Fig. 11. Coefficient of friction of Al 7075/Al2O3/5 wt.% graphite hybird composites.
improving the wear resistance. This behavior is in good agreement
with the results of Rosenberger et al. [64]. The effect of graphite
addition on friction coefficient is shown in Fig. 11. The presence
of graphite in the hybrid composite decreases the coefficient of
friction. The reduction in the coefficient of friction exhibited by
the hybrid composite relative to Al 7075 is due to the release of
graphite during their wear process which acted as the solid lubri-
cant. This was reduced about 51% than that of base alloy.
4. Conclusions
The effect of Al2O3 and graphite addition on the hardness of the
hybrid composites results in the increased with increasing Al2O3
ceramic particulates. The hardness of hybrid composites increases
with increasing Al2O3 and it was higher than that of base alloy in
all compositions. Addition of Al2O3 particle increases the tensile
strength, compression strength and flexural strength of the hybrid
composite and it was higher than that of base alloy. Addition of
graphite to aluminium alloy is known to decrease the hardness,
tensile strength, compression strength and flexural strength and it
was overcome by the addition of Al2O3 particulates in the hybrid
composites. The presence of graphite in the hybrid composites
exhibited a trend for keeping the wear, less due to the formation of
thin layer of graphite on the tribo surface. The governing wear
mechanism is abrasion and delamination. The presence of graphite
in the hybrid composite as also been able to decrease the coefficient
of friction of the composite and this is attributed to the release of
graphite which acted as the solid lubricant during the wear process.
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