Study of the Wear Behavior of Dual Solid Lubricant-Induced Ilmenite-Reinforced Hypereutectic Al-Si Alloy Composites

In the current study, an effort has been made to prepare aluminum alloy (hypereutectic Al-Si17Cu4Mg)-based composites reinforced with ilmenite (FeTiO₃; sea beach mineral). For the study, fine-sized (32-50 µm) and dual-sized (F:C:: 4:1, where F (32-50 µm) and C (75-106 µm)) ilmenite particles (15 wt.%) have been selected as reinforcement. In the metallic matrix, homogeneous distribution of ilmenite particles was observed through optical microscopy. Here, primary and secondary silicon refinement has also been observed up to ~ 60% as a result of incorporation of ilmenite particles. When compared to hypereutectic Al-Si17Cu4Mg alloy, the prepared composite samples exhibited ~ 10% higher wear resistance. Further, the presence of lubricating additives (graphite and tin) in the composite samples decreased the overall ~ 9% wear loss. The wear behavior of composite sample was compared to that of grey cast iron to evaluate the industrial utility of prepared sample. Based on these results, a detailed wear loss mechanism has also been proposed under 68.67 N as applied load for 3000 m sliding distance in which the dominance of delamination wear was observed over adhesive wear in SEM microstructures.