International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

Dry Sliding Wear Behavior of Silicon Carbide

Particulate Reinforced AA6061 Aluminum Alloy
Composites Produced via Stir Casting
S.Joseph Sekhar*

J.Jebeen Moses

Dept. of Mechanical Engineering,

St. Xavier's Catholic College of Engineering,
Nagercoil, Tamilnadu, India
josephsekhar@hotmail.com

Dept. of Mechanical Engineering,

St. Xavier's Catholic College of Engineering,
Nagercoil, Tamilnadu, India
jebeenmoses@gmail.com

Abstract

thermal expansion coefficients etc. The

excellent properties made them as a
demandable
material
in
several
industries, particularly in aircraft,
automotive and marine industries [7, 8].
The
development
in
production
techniques of AMCs caused the
progressive replacement of aluminum
alloys in many applications to enhance
product performance.

Stir casting is an economical method

to produce aluminum matrix composites
(AMCs). In the present work, Aluminum
alloy AA6061 reinforced with various
amounts (0, 5, 10 and 15wt. %) of SiC
particles were prepared. The matrix alloy was
melted in a furnace and stirred to form a
vortex. SiC particles were added to the
periphery of the vortex and the composite
melt was solidified in a permanent mold. The
microstructures of the AMCs were studied
using optical and scanning electron
microscopy. SiC particles were observed to
refine the grains and were distributed
homogeneously in the aluminum matrix. SiC
particle clusters were also seen in a few
places. SiC particles were properly bonded to
the aluminum matrix. Dry sliding wear
behavior was analyzed by Pin on Disc
apparatus. The reinforcement of SiC particles
improved the wear resistance of the
AMCs.The details of worn surface and wear
debris are also presented in this paper.

The production of AMCs with proper

distribution and bonding of ceramic
particles has been a challenge over the
years. Development and optimization of
production methods will improve the
properties of AMCs to fulfill the
requirement of various industries. AMCs
are presently produced using several
methods which can be classified into
solid state processing and liquid state
processing. The latter is preferred due to
its simplicity, lower cost, near net shape
and mass production [13].

Keywords: Metal Matrix Composites; Stir

Casting; Microstructure; Wear.

Stir casting is the widely adopted liquid

method to produce AMCs[4]. The
matrix material is melted in a furnace.
The melt is stirred to form a vortex. An
inert gas is passed to prevent the
formation of oxides. The ceramic
particles are fed at a predetermined rate
to the periphery of the vortex. The
stirring is continued till all the particles
are added. The composite melt is then

1. INTRODUCTION
Aluminum alloys reinforced with
various particulate ceramic particles are
universally known as aluminum matrix
composites (AMCs). AMCs display
superior properties such as high specific
strength, high elastic modules, excellent
friction and wear resistance and low
ISBN 978-93-80609-17-1
1441

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

poured into a mold. The solidified

composite can be further subjected to
heat treatment or other secondary
processing to improve the properties.
The critical process parameters are
temperature of the melt, stirrer speed,
stirring time, particle feed rate and
temperature of the mold. The limitations
of stir casting are poor distribution, wet
ability, porosity, interfacial reactions and
moderate volume fraction[6]. Proper
selection of process parameters can help
to produce sound AMCs [10].

aluminum alloy is presented in Table 1.

A coating was applied inside the
crucible to avoid contamination. The
temperature of the furnace was set at
7500C. The mechanical stirrer was
lowered into the aluminum melt after all
the rods were melted completely. The
stirrer was rotated at a constant speed of
300 rpm to form a vortex. Measured
quantity of SiC particles of size 30-40
m was gradually fed to the vortex at a
feed rate of approximately 15 g/min.
Stirring of the melt and feeding of SiC
particles was continued intermittently
for 30 minutes. The composite melt was
then poured into a die preheated to
3000C. Castings were taken with various
amounts of (0, 5, 10 and 15wt. %) of
SiC particles.

Some studies on the production and

characterization of aluminum alloy
reinforced SiC particles using stir
casting were reported in the literatures.
[6].prepared A359/SiC AMC using stir
casting and enhanced the wettablity
between SiC particles and the aluminum
matrix by adding magnesium. [12]
formed AA2014/SiC using stir casting
and recorded the tool during machine of
the AMC. [1] produced A356/Sic using
stir casting and compo casting and
analyzed the effect of casting
temperature on the distribution of SiC
particles. [9] fabricated AA6061/SiC
AMC using stir casting and studied the
effect of heat treatment on the fatigue
properties of the AMC. [2] developed
A356/SiC AMC by injecting SiC
particles into the molten aluminum alloy
and enhanced the distribution of SiC
particles. [14] observed the dispersion of
SiC particles all over the aluminum
matrix provides Orowan strengthening.

Specimens of size 6 mm x 6 mm x 6 mm
were prepared from the castings to carry
out microstructure and wear behavior.
The specimens were polished using
standard metallographic technique and
etched with Kellers reagent. The etched
specimens were observed using an
optical microscope and a scanning
electron microscope (SEM). The sliding
wear behavior of AA6061/SiC AMCs
was measured using a pin-on-disc wear
apparatus (DUCOM TR20-LE) at the
room temperature according to ASTM
G99-04 standard. The wear test was
conducted at a normal force of 25 N, a
sliding velocity and distance of 1 m/s
and 2500m respectively. The polished
surface of the pin was slid on a hardened
chromium steel disc. A computer aided
data acquisition system was used to
monitor the loss of height. The
volumetric loss was computed by
multiplying the cross sectional area of
the test pin with its loss of height. The
wear rate was obtained by dividing
volumetric loss to sliding distance. The
worn surfaces of the test specimens were
observed using SEM. The wear debris
which were scattered on the face of the
counterface were carefully collected and
characterized using SEM.

In this work, an attempt is made to

fabricate aluminum alloy AA6061
reinforced with SiC particles by stir
casting and study the effect of SiC
content on microstructure and wear
behavior of AA6061/SiC AMC.
2. EXPERIMENTAL PROCEDURE
AA6061 rods were placed in a graphite
crucible and was heated using an
electrical resistance furnace. The
chemical composition of AA6061
ISBN 978-93-80609-17-1
1442

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

3. RESULTS AND DISCUSSION

3.1 Microstructure
AMCs

of

granular distribution of ceramic particles

is preferred in AMCs over inter granular
distribution to obtain higher mechanical
and
tribological
properties.
The
distribution of reinforcement particles in
the matrix material takes place in three
stages as far as stir casting is concerned;
(a) distribution of particles in the melt as
a result of mixing, (b) distribution of
particles in the melt before pouring or
solidification and (c) redistribution of
particles as a result of solidification [5]
Adequate stirring causes the particles to
be dispersed effectively in the melt. The
mechanical stirring action drives the
particle into the melt. Suspension of SiC
particles in the melt throughout the
stirring period before pouring is needed
to achieve proper distribution. The
wetting action between SiC particle and
the aluminum melt provides resistance
to the free movement of SiC particle
within
the
melt.
Further,
the
incorporation of SiC particles into the
aluminum melt increases the viscosity of
the melt. The increase in viscosity leads
to retard the movement of SiC particle.
More the content of SiC particle, more
will be the viscosity and resistance to the
movement of particles. The above listed
factors results in better distribution of
SiC particles in the aluminum matrix.

AA6061/SiC

The optical and SEM micrographs of the

fabricated AA6061/SiC AMCs are shown in Fig.
1 and 2. Fig. 1a reveals the optical micrograph of
as cast AA6061. It depicts the typical dendritic
structure of aluminum. The dendritic structure
exhibits elongated primary -Al dendritic arms
having a high aspect ratio The high rate of
cooling during the solidification of the casting
results in the formation of dendritic structure.
The secondary precipitation phase Mg2Si is
observed along the dendritic boundaries due to
the high solubility limits of the alloying elements
such as Mg and Si.

Fig. 1b-d reveals the optical micrographs

of the fabricated AA6061/SiC AMCs.
The dendritic structure of the cast matrix
is completely disappeared. SiC particles
refined the dendritic structure into a
grainy structure. SiC acts as a grain
refiner. SiC particles play a significant
role during the solidification of the
composite melt, which results in grain
refinement. The following two factors
may contribute to the grain refinement.
The presence of distributed SiC particles
in the melt offers resistance to the freely
growing aluminum grains. The number
of grain nucleation sites increases with
the distribution of SiC particles in the
melt. Several SiC particles act as grain
nucleation sites due to constitutional
under cooling zone in front of the
particles. More the content of SiC
particles more will be the resistance to
grain growth and more nucleation sites.
As a result, formation of finer grains
takes place due to enhanced grain
refinement.
It is evident from the optical (Fig. 1b-d)
and SEM micrographs (Fig. 2) that the
distribution of SiC particles in the
aluminum matrix is fairly homogeneous.
There is no segregation of SiC particles
along the grain boundaries. Most of the
particles are located within the grains i.e.
the distribution is intra-granular. Intra

Fig.1. Optical micrograph of AA6061/ SiC

AMC with SiC content volume of; (a) 0%; (b) 5
%; (c) 10 %(d) 15 %.

ISBN 978-93-80609-17-1
1443

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

proper bonding enhance the load bearing

capacity of the AMC.
3.2 Sliding wear
AA6061/TiC AMCs

behavior

of

The effect of weight percentage of

SiCparticles on the wear rate of
AA6061/SiC AMCs is depicted in Fig.
3. It is evident from Fig. 3 that the SiC
particles reduces the wear rate
considerably. AA6061/15 wt.% SiC
AMC exhibits 30.5% lower wear rate
compared to unreinforced AA6061.This
is attributed to the high strength and
hardness of composites with SiC. The
relationship between material hardness
and material removal during sliding is
described as [11].

Fig. 2. SEM micrograph of AA6061/15 vol.%.

SiC at magnification; (a) 100x vol.%; (b) 400x;
(c) 750x and (d) 1000x.

The solidification pattern plays a role in

the redistribution of particles after
pouring. During solidification, several
factors such as convection current,
movement of the solidification front
against particles and buoyant motion of
particles influence the distribution of
particles in AMCs [3] If the
solidification front pushes the particles,
the distribution will be inter granular.
Otherwise, the intra granular distribution
will occur if the solidification front
engulfs the particles. Observing the
distribution of SiC particles, it appears
that the SiC particles were engulfed by
the solidification front which led to
intra-granular distribution.

Volume loss = (Wear coefficient x Applied load

x Sliding distance)

_____________________________

Hardness of material

Equation (1) shows that higher the

hardness of the material, lower will be
the wear rate. The enhanced hardness of
the composite offers resistance to the
cutting action of the counter surface
during sliding. A good interfacial
bonding between the SiC particle and
the aluminium matrix retards the
removal of particles during sliding.
When the weight percentage of SiC
particle increases, the contribution of
above factors further increases. As a
result, the wear rate is further reduced.

The SEM micrograph of AA6061/15wt.

% SiC AMC at higher magnification is
presented in Fig. 2d. The figure reveals
the details of the interface existing
between the aluminum matrix and SiC
particle. The interface is clear without
the presence of any reaction products.
SiC did not react with the aluminum to
produce any undesirable compounds.
The absence of any interfacial reaction
can be attributed to combination of
process parameters selected for stir
casting.
SiC
particles
are
thermodynamically stable under the
experimental conditions. SiC particle did
not decompose during casting. There are
no pores or voids are seen around SiC
particles which are properly bonded to
the matrix alloy. A clear interface and

The effect of weight percentage of SiC

particles on the morphology of the worn
surface of AA6061/SiC AMCs is shown
in Fig.4 The worn surface of the matrix
alloy in Fig.4a shows a large number of
parallel grooves. But the grooves are
blended at the edges due to piled up
plasticized matrix. The frictional heat
due to sliding between matrix alloy and
counter
surface
causes
plastic

ISBN 978-93-80609-17-1
1444

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

deformation. The wear mode is observed

to be adhesive. The worn surfaces of
AA6061/SiC AMCs (Fig.4b-d) show
distinct parallel grooves which bear
evidence to abrasive wear mode. The
edges of the grooves are sharper due to
the ploughing action of the counter
surface. Loose wear debris are also seen
on the worn surface. As the weight
percentage of SiC particle increases, the
number and size of pits on the worn
surface decreases.

Fig. 3 Effect of SiC content on wear rate of

AA6061/SiC stir cast composites

Fig.4 Worn surface of AA6061/SiC stir cast

composites containing SiC: (a) 0wt.%, (b)
5wt.%, (c) 10wt.% and (d) 15wt.%

Fig.5 Wear debris of AA6061/SiC stir cast

composites containing SiC: (a) 0wt.%, (b)
5wt.%, (c) 10wt.% and (d) 15wt.%

the local adhesion spreads and it is

removed in the form of thin plates.

The effect of weight percentage of SiC

particles on the morphology of wear
debris of AA6061/SiC AMCs is shown
in Fig.5 It reveals that the increase in
weight percentage of SiC particle results
in finer wear debris. The wear debris of
the matrix alloy in Fig.5a exhibits large
thin plate like morphology, which is due
to adhesive wear between matrix and
counter surface. Local welding or
adhesion takes place between the
plasticized asperities of matrix and
counter surface. As sliding continues,

When a SiC particle is added to the

matrix alloy, the local adhesion is
prevented and the wear mode shifts from
adhesion to abrasive. During the initial
stages of sliding of AA6061/5 wt. % SiC
AMC, some of SiC particles are
removed due to cutting action of counter
surface. When the matrix surrounding
the SiC particle is removed, SiC particle
is eventually pulled out. These SiC
particles are trapped between the

ISBN 978-93-80609-17-1
1445

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

specimen and the counter surface

converting two body abrasion into three
body abrasion. Rolling is promoted to
over sliding which reduces the wear rate.
The three body abrasion generates finer
wear debris. Fig.4c and d show that the
weight percentage of SiC increases the
milling action. As a result it increases
the forms of the finer spherical debris.

[2] Amirkhanlou, S., Niroumand, B.,

2010.
Synthesis
and
characterization
of
356-SiCp
composites by stir casting and
compo
casting
methods.
Transactions of Nonferrous Metals
Society of China 20, S788-S793.
[3] Bauri, R., Yadav, D., Suhas, G.,
2011. Effects of friction stir
processing (FSP) on microstructure
and properties of AlTiC in situ
composite. Materials Science and
Engineering A 528, 47324739.

4. CONCLUSIONS
In the present work, AA6061/SiC AMCs
were successfully fabricated using stir
casting. The effect of SiC content on
microstructure and wear behavior was
analyzed. The distribution of SiC in the
aluminium
matrix
was
fairly
homogeneous. The distribution of SiC
particles was observed to be intra
granular. SiC particles refined the grains
of matrix alloy and were properly
bonded to the matrix. The interface
between the SiC particle and the
aluminium matrix was clean without the
presence of reaction products, pores and
voids. SiC particles enhanced the wear
resistance of the composite. But reduced
the ductility of the composite.
AA6061/15 wt. % SiC AMC exhibited
30.5% lower wear rate when compared
with unreinforced AA6061 alloy. The
increase in SiC content shifted the wear
mode from adhesive to abrasive. The
size of wear debris became finer when
the content of SiC particle was increased
due to three body abrasion.

[4] Gopalakrishnan, S., Murugan, N.,

2012. Production and wear
characterization of AA 6061 matrix
titanium
carbide
particulate
reinforced composite by enhanced
stir casting method. Composites:
Part B 43, 302308.
[5] Hashim, J., Looney, L., Hashmi,
M.S.J.,
1999.
Metal
matrix
composites: production by the stir
casting method. Journal of Materials
Processing Technology 92-93, 1-7.
[6] Hashim, J., Looney, L., Hashmi,
M.S.J., 2001. The enhancement of
wettablity of SiC particles in cast
aluminum
matrix
composites.
Journal of Materials Processing
Technology 119, 329-335.

REFERENCES
[1] Akhlaghi, F., Lajevardi, A.,
Maghanaki, H.M. 2004. Effects of
casting
temperature
on
the
microstructure and wear resistance
of
compocast
A356
SiCp
composites. Journal of Materials
Processing Technology 155156,
18741880.

[7] Kalaiselvan, K., Murugan, N.,

Parameswaran, S., 2011. Production
and characterization of AA6061
B4C stir cast composite. Materials
and Design 32, 40044009.
[8] Kok, M., 2005. Production and
mechanical properties of Al2O3
particle-reinforced 2024 aluminium

ISBN 978-93-80609-17-1
1446

International Conference on Recent Advances in Mechanical Engineering and Interdisciplinary Developments [ICRAMID - 2014]

alloy composites. Journal of

Materials Processing Technology
161, 381387.

and Engineering A 483484, 148

152.

[9] Mahadevan, K., Raghukandan, K.,

Pai, B.C, Pillai, U.T.S., 2008.
Influence of precipitation hardening
parameters on the fatigue strength
of AA 6061-SiCp composite. Journal
of Materials Processing Technology
198, 241-247.
[10] Prabu, S.B., Karunamoorthy, L.,
Kathiresan S., Mohan, B., 2006.
Influence of stirring speed and
stirring time on distribution of
particles in cast metal matrix
composite. Journal of Materials
Processing Technology 171, 268
273.
[11] S. Kumar, V.S. Sarma, and B.S.
Murty, Influence of In Situ Formed
TiB2 Particles on The Abrasive
Wear Behaviour of Al4Cu Alloy,
Mater. Sci. Eng. A, 2007, 12, p
160164
[12] Sahin, Y., 2003. Preparation and
some properties of SiC particle
reinforced
aluminium
alloy
composites. Materials and Design
24, 671679.
[13] Taha, M.A., 2001. Practicalization
of cast metal matrix composites
(MMCCs). Materials and Design 22,
431-441.
[14] Zhang. Z, Chen, D.L., 2008.
Contribution
of
Orowan
strengthening effect in particulate
reinforced
metal
matrix
nanocomposites. Materials Science
ISBN 978-93-80609-17-1
1447