Citation:

Niranjan Hugar, Venkata Narayana B, Sunil Waddar, Manjunath K, Mohan Kumar K, Santosh N, 2024. TiO₂ Particles Influence on the Wear Conduct of an Aluminium AA6061/Red Mud Hybrid Composite, ESP Journal of Engineering & Technology Advancements  4(1): 17-31.

Abstract:

The current study was carried out with the new goal of developing and characterising high-performance hybrid Aluminium AA 6061/Red Mud composites with varied wt.% TiO2 (0, 2, and 4% wt.%) for tribological applications. In this regard, ultrasonic-assisted stir casting is used to create composites of various compositions and machine them to ASTM G99-95a standards. The pin-on-disc wear test is performed on a Ducom TR-12 tribometer in accordance with the L27 Orthogonal Array (OA) for varying load parameters of 10 N, 20 N, and 30 N, sliding distances of 500 m, 1500 m, and 2500 m, and disc rotation speeds of 200 RPM, 400 RPM, and 600 RPM, while the hardness test is performed on a Brinell Hardness tester. The results show that the Specific Wear Rate (SWR) and Coefficient of Friction (COF) decrease as the wt.% of TiO2 increases, although the hardness values rise for the same wt.% of reinforcements. Response Surface Methodology is used to validate the results further (RSM). The hall petch strengthening process is mostly responsible for the increase in hardness and wear resistance.

References:

[1] Kempaiah, U.N.; Santhosh, N.; Kumar, D.H.; Chelgeri, A.H.; Vishnu, P.; Raorane, S. Characterization of High performance Al 5083/SiC/Fly Ash hybrid metal matrix composite for advanced Aerospace Applications. Int. J. Adv. Innov. Res. 2015, 3, 334–341.
[2] Gowda, A.C.; Girish, D.P.; Santhosh, N.; Kumar, A. Study of Wear Characteristics of Aluminium/B4C/CNT Hybrid Composites under the Influence of Controlled Factors. Nano Trends A J. Nanotechnol. Its Appl. 2016, 18, 21–32.
[3] Santhosh, N.; Kempaiah, U.N.; Venkateswaran, S. Vibration Mechanics of Hybrid Al 5083/SiC/Fly Ash Composite Plates for its Use in Dynamic Structures. J. Exp. Appl. Mech. 2017, 8, 11–18.
[4] Santhosh, N.; Kempaiah, U.N.; Sajjan, G.; Gowda, A.C. Fatigue Behaviour of Silicon Carbide and Fly Ash Dispersion Strengthened High Performance Hybrid Al 5083 Metal Matrix Composites. J. Miner. Mater. Charact. Eng. 2017, 5, 274–287.
[5] Santhosh, N.; Kempaiah, U.N. Vibration Characterization of SiC and Fly Ash Dispersion Strengthened Aluminium 5083 Composites. J. Aerosp. Eng. Technol. (JoAET) 2017, 7, 61–72.
[6] Santhosh, N.; Kempaiah, U.N.; Bhanupratap, R. Critically Damped Composite plates for Structural applications in Smart Cities. In Proceedings of the International Conference on Development of Smart Cities, Interface, Governance & Technology, Dr Ambedkar Institute of Technology, Bangalore, Karnataka, India, 9–10 September 2016.
[7] Sadashiva, M.; Shivanand, H.K.; Rajesh, M.; Santhosh, N. Corrosion Behavior of Friction Stir Welded Al 6061 Hybrid Metal Matrix Composite Plates. In Proceedings of the International Conference on Advances in Mechanical Engineering Sciences (ICAMES-17), PESCE, Mandya, Karnataka, India, 21–22 April 2017.
[8] Santhosh, N.; Kempaiah, U.N.; Gowda, A.C.; Rao, S.; Hebbar, G. Evaluation of Corrosion Mechanics of Silicon Carbide and Fly Ash Reinforced Hybrid Aluminium Metal Matrix Composites. In Proceedings of the International Conference on Emerging Research in Civil, Aeronautical & Mechanical Engineering, ERCAM 2017, Nitte Meenakshi Institute of Technology, Bengaluru, India, 21 July 2017; pp. 214–218.
[9] Ramesha, K.; Sudershanan, P.D.; Santhosh, N. Mechanical and Thermal characterization of Friction Stir weld joints of Al-Mg alloy. In Proceedings of the International Conference on Emerging Trends in Mechanical Engineering (ETME), Mandya, India, 27–29 December 2017.
[10] Santhosh, N.; Kempaiah, U.N. Effect of heat treatment and reinforcements on mechanical properties of aerospace grade Aluminium composites at elevated temperatures. In Proceedings of the 2nd International Conference on Recent Research Emerging Trends in Mechanical & Civil Engineering, (ICRRETMCE-2018), REVA University, Bengaluru, Karnataka, India, 13–14 July 2018.
[11] Santhosh, N.; Kempaiah, U.N. Effect of silicon carbide and fly ash on characteristics of Aluminium matrix composites for improved dynamic performance. In Proceedings of the Advanced Ceramics and Nano materials for Sustainable Development (ACeND-2018), CHRIST, Bangalore, Karnataka, India, 19–21 September 2018.
[12] Santhosh, N.; Kempaiah, U.N.; Sunil, G.S. Novel Aluminium–SiC–Fly Ash Hybrid Metal Matrix Composites: Synthesis and Properties. J. Aerosp. Eng. Technol. 2017, 7, 26–33.
[13] Santhosh, N.; Kempaiah, U.N. Influence of Ceramic Particulate Reinforcements on Fly Ash Dispersion Strengthened Composites for Aircraft Structures. J. Aerosp. Eng. Technol. (JoAET) 2017, 7, 38–45.
[14] Trzepieci ´nski, T.; Najm, S.M.; Sbayti, M.; Belhadjsalah, H.; Szpunar, M.; Lemu, H.G. New Advances and Future Possibilities in Forming Technology of Hybrid Metal–Polymer Composites Used in Aerospace Applications. J. Compos. Sci. 2021, 5, 217.
[15] Santhosh, N.; Khan, G.M.; Dubey, A.; Patel, S.; Phookan, A. Fabrication and Characterization of Tensile Properties of Aluminum 5083/Silicon Carbide/Fly Ash Composites for Advanced Engineering Applications. J. Polym. Compos. 2018, 6, 6–9.
[16] F. Rana, D.M. Stefanescu, Friction properties of Al-l.5 Pet Mg/SiC particulate metal-matrix composites, Metallurgical and Materials Transactions A 20 (1989) 1564–1566.
[17] K.S. Al Rubaie, H.N. Yoshimura, D.B. Mello, Two-body abrasive wear of Al–SiC composites, Wear 233–235 (1999) 444–454.
[18] Y. Sahin, Optimization of testing parameters on the wear behaviour of metal matrix composites based on the Taguchi method, Materials Science and Engineering A 408 (2005) 1–8.
[19] 50. Mokashi, I.; Afzal, A.; Khan, S.A.; Abdullah, N.A.; Bin Azami, M.H.; Jilte, R.; Samuel, O.D. Nusselt number analysis from a battery pack cooled by different fluids and multiple back-propagation modelling using feed-forward networks. Int. J. Therm. Sci. 2020, 161, 106738.
[20] Santhosh N, Manjunath N, Mahesh H R, Potentiodynamic Corrosion Characterization of Hybrid Aluminium Composites for Advanced Engineering Applications, International Journal of Engineering and Advanced Technology, 9(3), 1434-1437, 2020.
[21] Akhtar, M.; Sathish, T.; Mohanavel, V.; Afzal, A.; Arul, K.; Ravichandran, M.; Rahim, I.; Alhady, S.; Bakar, E.; Saleh, B. Optimization of Process Parameters in CNC Turning of Aluminum 7075 Alloy Using L27 Array-Based Taguchi Method. Materials 2021, 14, 4470.
[22] M. Sadashiva, N.M. Siddeshkumar, J. Monica, M.R. Srinivasa, N. Santhosh, S. Praveenkumar, Hardness and Impact Strength Characteristics of Al based Hybrid Composite FSW Joints, 2022. Int. J. Vehicle Structures & Systems, 14(1), 13-17, https://doi.org/10.4273/ijvss.14.1.04 (SCOPUS). Print (ISSN 0975-3060) and Online (ISSN 0975-3540)
[23] Meignanamoorthy, M.; Ravichandran, M.; Mohanavel, V.; Afzal, A.; Sathish, T.; Alamri, S.; Khan, S.; Saleel, C. Microstructure, Mechanical Properties, and Corrosion Behavior of Boron Carbide Reinforced Aluminum Alloy (Al-Fe-Si-Zn-Cu) Matrix Composites Produced via Powder Metallurgy Route. Materials 2021, 14, 4315.
[24] K. Ramesha, N. Santhosh, K. Kiran, N. Manjunath, H. Naresh, Effect of the Process Parameters on Machining of GFRP Composites for Different Conditions of Abrasive Water Suspension Jet Machining, 9(94):1-11,2019. [Web of Science and Scopus]
[25] Sathish, T.; Kaladgi, A.; Mohanavel, V.; Arul, K.; Afzal, A.; Aabid, A.; Baig, M.; Saleh, B. Experimental Investigation of the Friction Stir Weldability of AA8006 with Zirconia Particle Reinforcement and Optimized Process Parameters. Materials 2021, 14, 2782.
[26] BA Praveena, N Santhosh, DP Archana, Abdulrajak Buradi, E Raj, C Chanakyan, Ashraf Elfasakhany, Dadapeer Basheer, Influence of Nanoclay Filler Material on the Tensile, Flexural, Impact, and Morphological Characteristics of Jute/E-Glass Fiber-Reinforced Polyester-Based Hybrid Composites: Experimental, Modeling, and Optimization Study, Journal of Nanomaterials Vol. 2022, Article ID 1653449, 17 pages https://doi.org/10.1155/2022/1653449.
[27] Nagaraja, S.; Kodandappa, R.; Ansari, K.; Kuruniyan, M.S.; Afzal, A.; Kaladgi, A.R.; Aslfattahi, N.; Saleel, C.A.; Gowda, A.C.; Bindiganavile Anand, P. Influence of Heat Treatment and Reinforcements on Tensile Characteristics of Aluminium AA 5083/Silicon Carbide/Fly Ash Composites. Materials 2021, 14, 5261. https://doi.org/10.3390/ma14185261.
[28] G Ravichandran, G Rathnakar, N Santhosh, R Suresh, Wear Characterization of HNT filled Glass-Epoxy Composites using Taguchi’s Design of Experiments and Study of Wear Morphology, Composites Theory and Practice, 2020, 20(2), 85-91.
[29] G Ravichandran, G Rathnakar, N Santhosh, R Thejaraju, Antiwear Performance Evaluation of Halloysite Nanotube (HNT) Filled Polymer Nanocomposites, International Journal of Engineering and Advanced Technology, 2019, 9(1), 3314-3321.
[30] Srinivasa M. R., Y. S. Rammohan, Sadashiva M., Santhosh N, Effect of Shock Waves on the Hardness of Graphene Reinforced Aluminium Composites, Journal of Polymer & Composites, 8(1), 32-38, 2020.
[31] Ramesha K, Sudersanan, P D, Santhosh N, Sasidhar Jangam. 2021. “Corrosion Characterization of Friction Stir Weld Joints of Dissimilar Aluminum Alloys.”, EAI/Springer Innovations in Communication and Computing, https://doi.org/10.4108/eai.16-5-2020.2304097
[32] Ramesha K, Sudersanan, P D, Santhosh N, Sasidhar Jangam. Sustainable Processing of Dissimilar Aluminium Alloy Joints by Friction Stir Welding, IOP Conf. Series: Materials Science and Engineering 1132 (2021) 012029, IOP Publishing, https://iopscience.iop.org/article/10.1088/1757-899X/1132/1/012029.
[33] Ramesha K, Sudersanan, P D, Santhosh N, Sasidhar Jangam, (2021). Design and optimization of the process parameters for friction stir welding of dissimilar aluminium alloys. Engineering and Applied Science Research, 48(3), 257-267. https://ph01.tci-thaijo.org/index.php/easr/article/view/241021.
[34] K. Ramesha, P. D. Sudersanan, Prem Kumar Mahto, Shaikh Mohammed Ismail, Ashwin C. Gowda, N. Santhosh and V. Umesh, Influence of heat treatment on the tensile and hardness characteristics of friction stir weld joints of dissimilar aluminium alloys, AIP Conference Proceedings Vol. 2421, Issue -1, Pages 030001 (2022); https://doi.org/10.1063/5.0076766 (SCOPUS). ISSN: 0094-243X (print) 1551-7616 (web)
[35] K. Ramesha, P.D. Sudersanan, A.C. Gowda, N. Santhosh, S. Jangam, N. Manjunath, Friction Stir Welding of Dissimilar Aluminium Alloys for Vehicle Structures, Int. J. Vehicle Structures & Systems, Vol. 14 No. 1 (2022), 5 – 9, https://doi.org/10.4273/ijvss.14.1.02 (SCOPUS). Print (ISSN 0975-3060) and Online (ISSN 0975-3540)
[36] N. Santhosh , B. A. Praveena , H. V. Srikanth , Santosh Angadi , Amaresh Gunge , M. Rudra Naik , G. Shankar , K. Ramesha , G. Ravichandran, Experimental Investigations on Static, Dynamic, and Morphological Characteristics of Bamboo Fiber-Reinforced Polyester Composites, Hindawi, International Journal of Polymer Science Volume 2022, Article ID 1916877, 11 pages https://doi.org/10.1155/2022/1916877.
[37] N Santhosh , B A Praveena, A Chandrashekar, V Mohanavel, S Raghavendra, Dadapeer Basheer, Wear behaviour of aluminium alloy 5083/SiC/fly ash inoculants based functional composites– optimization studies, Mater. Res. Express 9 (2022) 076513, https://doi.org/10.1088/2053-1591/ac8229.
[38] Nagaraja, S; Nagegowda, K.U.; Kumar V, A.; Alamri, S.; Afzal, A.; Thakur, D.; Kaladgi, A.R.; Panchal, S.; Saleel C, A. Influence of the Fly Ash Material Inoculants on the Tensile and Impact Characteristics of the Aluminum AA 5083/7.5SiC Composites. Materials 2021, 14, 2452. https://doi.org/10.3390/ma14092452.
[39] Bharath, V.; Auradi, V.; Kumar, G.B.V.; Nagaral, M.; Chavali, M.; Helal, M.; Sami, R.; Aljuraide, N.; Hu, J.W.; Galal, A.M. Microstructural Evolution, Tensile Failure, Fatigue Behavior and Wear Properties of Al2O3 Reinforced Al2014 Alloy T6 Heat Treated Metal Composites. Materials 2022, 15, 4244. https://doi.org/10.3390/ma15124244.

Keywords:

Wear, Hardness, Aluminium AA 6061, Red Mud, TiO₂.