Fabrication and characterization of ZrO₂ reinforced Fe-20Cr alloy composites

Abstract

The reinforcement effects of the ZrO2 and the wear and mechanical behaviour of (Fe,Cr)-based alloy composites were investigated. The (100-x) (Fe80Cr20) -(x) ZrO2 composites were fabricated via powder metallurgy. The iron-chromium and ZrO2 powders were efficiently milled and mixed in ball mill. In the Fe80Cr20 alloy, the effect was investigated by changing the ZrO2 composition by 5%, 10%, and 15%. The microstructure feature and consequent wear behaviour of iron and chromium alloys have been studied using the diversified alloy compositions, various sintering temperatures, and various substrates. The blended powder mixture was cold compacted and sintered at 1300°C. The scanning electron microscopy (SEM), elemental mapping, and X-ray diffraction techniques were utilized to assess the microstructural properties of the sintered composites. In addition, the mechanical properties such as hardness, flexural strength, and porosity were examined with variations in ZrO2 composites. The dry sliding wear tests with various normal loads and a constant sliding distance were used to find the composites wear behaviour. The composite containing 10% ZrO2 has shown the maximum flexural strength with 1470 MPa, and hardness 359.8 HV10, respectively, compared to 5% ZrO2 and 15% ZrO2. With a concentration of 10 wt.% ZrO2, the wear resistance is found to be significantly enhanced, while after 10 wt.% ZrO2, its properties deteriorate. In addition to having improved interfacial bonding, lower porosity, and microstructure uniformity, Fe-10