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2 Composites Theory and Practice

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Modelling and optimization of wear parameters of Al 4032 reinforced with coal ash using Taguchi and RSM approach

Gudimetla Avinash, Lingaraju Dumpla, Sambhu Prasad S.

Composites Theory and Practice

2021

R. 21, nr 1-2

3--11

The present study aimed to analyze the wear behaviour of composites synthesized by reinforcing Al 4032 with 2, 4, 6 wt.% of coal ash using the stir casting technique. Wear testing was performed on the composites at room temperature in the absence of lubrication using a pin-on-disc tribometer considering the process parameters as wt.% of reinforcement, speed and load. Micro structural characterization using scanning electron microscope (SEM) and energy dispersive X-ray analysis (EDX) was performed on the cast composites to ascertain the existence of the reinforcement along with its distribution in the prepared composites. The Taguchi L16 orthogonal array was utilized to design experiments to study the significance of the process parameters on the wear rate. A mathematical model was developed for the wear rate using response surface methodology (RSM). 6 wt.% reinforcement, at the speed of 100 rpm and 10 N load were the obtained optimized parameters for the minimum wear rate. Surface plots as well as contour plots were analyzed to understand the consequence of the process parameters on the wear rate. The analysis of variance (ANOVA) revealed that speed with 76.10 % was the most prominent parameter followed by load and reinforcement with 11.23 and 9.42% respectively.

Investigation of mechanical and tribological behavior of Al 4032-SiHGM MMC

Gudimetla Avinash, Lingaraju D., Prasad S. Sambhu

Composites Theory and Practice

2020

R. 20, nr 3-4

142--156

The present study is aimed at identifying the influence of silicon hollow glass microspheres (SiHGM) on a newly engineered metal matrix composite. Silicon micro balloons of various wt.% (2, 4, 6) are reinforced in to aluminium 4032 to produce a composite using the stir casting technique. The mechanical properties of the composite such as hardness, tensile and compressive strength were measured. The dry sliding wear test was conducted on the produced specimens to measure the wear rate and coefficient of friction. The results revealed that the properties of the composite are better with an increase in the wt.% of reinforcement. The presence of reinforcement in the composites was identified using Energy Dispersive X-Ray analysis (EDX). The grain boundaries and grain refinement for various compositions of reinforcements and worn surfaces were analyzed using Scanning Electron Microscope (SEM) micrographs. The process parameters for the minimum wear rate and coefficient of friction were identified and optimized by using the Taguchi L16 orthogonal array. Analysis of variance (ANOVA) was used to determine the percentage contribution of each process parameter. Multi-response optimization was carried out using Grey relational analysis (GRA) to optimize the process parameters to attain a minimum coefficient of friction and wear rate. The variation in wear rate and coefficient of friction are analyzed with respect to reinforcement (wt.%), speed (rpm) and load (N).