Study of Wear Rate of AA7050-7.5 B4C-T6 Composite and Optimization of Response Parameters using Taguchi Analysis

Abstract

High-strength-to-weight ratio materials are crucial for the automotive and aerospace sectors, driving the demand for advanced solutions. Traditional monolithic materials fall short of meeting these requirements, prompting the exploration of ceramic-based metal matrix composites. Among these, the Al/B4C composite stands out for its exceptional wear-resistant properties, attributed to its heightened hardness and shear resistance. This study investigates the wear performance of AA 7050-7.5% B4C-T6 Composite, produced via flux (K2TiF6) assisted stir casting method. The wear rate serves as the primary performance metric, evaluated using a pin-on-disc tribometer. Experimental design employs a Taguchi L9 orthogonal array, facilitating systematic analysis. Taguchi Analysis optimizes the process parameters, revealing insights into their impact on wear performance. The wear rate directly correlates with both applied load and sliding distance, indicating higher wear with increased stress and sliding duration. Additionally, the sliding speed intermittently influences the wear rate due to a Mechanical Mix Layer (MML) presence, highlighting the complex interplay of factors influencing wear behaviour. In summary, this research underscores the potential of AA 7050-7.5% B4C-T6 Composite as a promising wear-resistant material, offering valuable insights into optimizing its performance through controlled process parameters.