article · Engineering Reports
Aluminium 6063 matrix composites are utilised in wear-resistant components because they offer high specific strength, light weight, and good resistance to corrosion. A study tested the wear behaviour of these composites when reinforced with combinations of titanium carbide, silicon nitride, and zinc oxide particles. Testing was carried out on a pin-on-disc machine across varying applied loads, sliding velocities, sliding distances, and reinforcement concentrations. Performance was tracked using specific wear rate and the coefficient of friction. The lowest wear rate was 4.55 cubic millimetres per Newton-metre at a 60 Newton load, two metres per second velocity, 1000 metres distance, and 4.5 weight percent reinforcement. The lowest friction coefficient was 0.276 at 60 Newtons, four metres per second, 2000 metres, and 1.5 weight percent reinforcement. An Adaptive Neuro-Fuzzy Inference System model successfully predicted these wear responses.
Components in machinery and transport suffer damage and energy loss from friction and surface wear. By combining aluminium with select ceramic particles, engineers can develop materials that are both lightweight and durable. Understanding how these composites perform under friction helps manufacturers choose optimal material blends and operational limits to prevent premature part failure.
This research provides performance data and predictive modelling that could benefit designers of wear-resistant components in industries requiring lightweight, durable metals. With testing conducted at laboratory scale using a pin-on-disc configuration alongside computational modelling, the technology sits at an applied testing stage and requires further development before integration into real-world manufacturing.
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ABSTRACT Aluminum 6063 matrix composites are widely employed in wear‐resistant applications due to their high specific strength, lightweight nature, and excellent corrosion resistance. This study conducted a wear analysis on Al6063 composites reinforced with varying concentrations of titanium carbide (TiC), silicon nitride (Si 3 N 4 ), and zinc oxide (ZnO) using a pin‐on‐disc apparatus. The investigation focused on four key input variables: applied load, sliding velocity, sliding distance, and a combined reinforcement composition ( R ) of TiC + ZnO + Si 3 N 4 . Wear performance was evaluated using two indicators—specific wear rate (SWR) and coefficient of friction (COF). The minimum SWR observed was 4.55 mm 3 /Nm under optimized conditions: 60 N load, 2 m/s sliding velocity, 1000 m sliding distance, and 4.5 wt% reinforcement. The lowest COF, 0.276, was achieved at a 60 N load, 4 m/s velocity, 2000 m distance, and 1.5 wt% reinforcement. The reduction in wear rate is attributed to the synergistic effect of the reinforcements, which enhance load‐bearing capacity and abrasion resistance due to their hardness and thermal stability. Increased reinforcement content led to notable reductions in both SWR and COF, whereas higher loads tended to increase both responses. An Adaptive Neuro‐Fuzzy Inference System (ANFIS) was employed to predict output responses based on the input parameters.
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DOI: 10.1002/eng2.70359
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