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The purpose of this technical paper is to investigate the friction and wear behaviour of heat treated Al 6061 alloy and Al 6061 SiC‐graphite particulate reinforced hybrid composites subjected to different ageing durations.

The composites have been prepared by stir casting process with varying percentages of SiC and graphite particles. The cast 6061 alloy and its composites were subjected to solutionising treatment at a temperature of 803 K for 1 hr followed by quenching in water. The quenched samples were then subjected to artificial ageing for different durations of 4, 6, 8 hr at a temperature of 448 K. Tests were performed on heat treated Al 6061 alloy and its composites using pin‐on‐disc apparatus. Hardness measurements were also made on the specimens. The wear surfaces of the composites were analyzed using scanning electron microscopy.

During wear test of specimens the wear resistance of the hybrid composites was found to increase with increase in ageing durations. The microscopic examination of the wear surfaces shows that the base alloy and composites wear primarily because of abrasion and delamination. The hardness result shows that the hardness of the composites increased with decreasing weight percentage of graphite particles.

The content of this paper is fully research oriented and the finding from this investigation will be useful for society and also the automobile industries, especially in the making of brake drums.

The reliable performance of critical components working under extreme conditions is paramount to the safe operation of aircraft, and material selection is critical. Copper alloys are an obvious choice for such applications whenever a combination of transport, mechanical and tribological properties is required. However, low strength and hardness issues require development of new copper alloys and composites to improve service life and reliability. This study aims to investigate the effect of carbon nanotubes as reinforcement phase in copper-matrix composites.

The development of novel copper-based composites refined to the nanoscale was envisaged through mechanical milling of mixtures containing copper and carbon nanotubes (2 Wt.%). Milling took place in a planetary ball mill for times varying between 1 h and 16 h at 400 rpm. A ball-to-powder ratio of 20:1 and alumina vial and copper spheres were used under dry conditions or with addition of isopropyl alcohol. Scanning electron microscopy/energy dispersive spectroscopy, size distribution, Raman spectroscopy and X-ray diffraction were used to study the produced powders.

Attained results show that mechanical milling of the studied system produces nanostructured powders containing second-phase carbon nanotubes homogeneously distributed in the metallic matrix, together with severe copper grain refinement. This should correspond to increased residual microstresses, envisaging significant improvement of mechanical properties of the produced copper composites.

The novelty of the work resides in the use of carbon nanotubes for the reinforcement of copper, and on the systematic microstructural characterisation of the produced composites.

The purpose of this paper is to understand the effect of graphite content on the properties of aluminum alloy/silicon carbide/granite (Al/SiC/Gr) composites.

Hardness and wear tests were applied to the powder metallurgical composites, and microstructural characterization was conducted.

Optimum graphite content for maximum wear resistance is reported as weight 6 per cent.

Results of this study may help light weight Al/SiC/Gr composites to be used in different industrial applications.

Since, wear is the one of the most commonly encountered industrial problems leading to frequent replacement of components there is a need to develop metal matrix composites (MMCs) for achieving better wear properties. The purpose of this paper is to fabricate aluminum MMCs to improve the dry sliding wear characteristics. An effective multi-response optimization approach called the principal component analysis (PCA) was used to identify the sets of optimal parameters in dry sliding wear process.

The present work investigates the dry sliding wear behavior of graphite reinforced aluminum composites produced by the molten metal mixing method by means of a pin-on-disc type wear set up. Dry sliding wear tests were carried on graphite reinforced MMCs and its matrix alloy sliding against a steel counter face. Different contact stress, reinforcement percentage, sliding distance and sliding velocity were selected as the control variables and the response selected was wear volume loss (WVL) and coefficient of friction (COF) to evaluate the dry sliding performance. An L25 orthogonal array was employed for the experimental design. Optimization of dry sliding performance of the graphite reinforced MMCs was performed using PCA.

Based on the PCA, the optimum level parameters for overall principal component (PC) of WVL and COF have been identified. Moreover, analysis of variance was performed to know the impact of individual factors on overall PC of WVL and COF. The results indicated that the reinforcement percentage was found to be most effective factor among the other control parameters on dry sliding wear followed by sliding distance, sliding velocity and contact stress. Finally the wear surface morphology of the composites has been investigated using scanning electron microscopy.

Various manufacturing techniques are available for processing of MMCs. Each technique has its own advantages and disadvantages. In particular, some techniques are significantly expensive compared to others. Generally the manufacturer prefers the low cost technique. Therefore stir casting technique which was used in this paper for manufacturing of Aluminum MMCs is the best alternative for processing of MMCs in the present commercial sectors. Since the most important criteria of a dry sliding wear behavior is to provide lower WVL and COF, this study has intended to prove the application of PCA technique for solving multi objective optimization problem in wear applications like piston rings, piston rods, cylinder heads and brake rotors, etc.

Application of multi-response optimization technique for evaluation of tribological characteristics for Aluminum MMCs made up of graphite particulates is a first-of-its-kind approach in literature. Hence PCA method can be successfully used for multi-response optimization of dry sliding wear process.

Aluminium alloys are frequently applied in automotive and other industries, since they provide mass reduction. Besides positive effects, aluminium alloys have their shortcomings reflected, first of all, in inappropriate tribological properties of these materials. The aim of this research was to enable the production of cheap aluminium alloy matrix composite with favourable combination of structural, mechanical and tribological properties, focusing on the tribological behaviour.

The A356 Al-Si alloy was used as a matrix for producing metal matrix composites in compocasting process. Three different materials, in form of particles, were added to the matrix (Al₂O₃, SiC and graphite). Hardness and tribological properties (wear, friction and wear mechanism) of heat-treated (T6) samples were examined and compared. Tribological tests were carried out on ball-on-block tribometer under dry sliding conditions. Sliding was linear (reciprocating). Counter body was alumina ball. Average velocity was 0.038 m/s (max. 0.06 m/s), sliding distance was 500 m and normal load was 1 N.

The effect of two different ceramic particles and graphite particles on tribological properties of obtained composites was evaluated. Wear resistance of composites reinforced with SiC particles was higher and coefficient of friction was lower compared to the composite reinforced with Al₂O₃ particles. A dual hybrid composite (with SiC and graphite particles) showed the lowest value of wear rate and friction coefficient. Dominant wear mechanism for all tested material was adhesion.

It seems useful to continue the work on developing hybrid composites containing soft graphite particles with A356 Al-Si alloy as matrix. The major task should be to improve particles distribution (especially with higher graphite content) and to explore tribological behaviour in diverse working conditions.

Particulate composites with A356 aluminium alloy as a matrix produced in compocasting process using ceramic particles (Al₂O₃, SiC) were investigated in many researches, but there are only few detailed analyses of dual composites (with the addition of ceramic and graphite particles). In some previous studies, it was shown that compocasting process, as relatively cheap technology, can obtain good structural and mechanical characteristics of composites. In this study, it was shown that even a low graphite content, under specified conditions, can improve tribological properties.

The purpose of this paper is to explore the use of fly ash and graphite particles as low cost reinforcing materials for improved wear resistance, enhanced mechanical properties and reduction in density of hybrid composites.

The AlSi10Mg/fly ash/graphite (Al/FA/Gr) hybrid composite was synthesised by stir casting method. The dry sliding wear and friction behaviour of hybrid composites were studied using pin-on-disc machine by varying parameters like load and weight fraction of fly ash, and compared with the base metal alloy and aluminium-graphite composite. The tests were conducted with a constant sliding speed of 2 m/s and sliding distance of 2,400 m.

The hybrid composites exhibit higher hardness, higher tensile strength and lower density when compared to unreinforced alloy and aluminium-graphite composite. The incorporation of fly ash and graphite particles as reinforcements caused a reduction in the wear rate and coefficient of friction (COF) of the hybrid composites. The improvement in the tribological characteristics occured due to the load carrying capacity of hard fly ash particles and the formation of a lubricating film of graphite between the sliding interfaces. The wear rates and COF of unreinforced aluminium alloy and composites increase with an increase in the applied normal load. The wear rates and COF of hybrid composites decrease with an increase in the fly ash content. 9 wt.% fly ash and 3 wt.% graphite reinforced hybrid composite exhibited the highest wear resistance and lowest COF at all applied loads. Abrasive wear and delamination were dominant in the mild wear regime of aluminium alloy and composites. Due to subsurface deformation and crack propagation, plate-like wear debris were generated during delamination wear. In the severe wear regime, the dominant wear mechanism was adhesive wear with formation of transfer layers.

It is expected that these findings will contribute towards the development of lightweight and low cost aluminium products with improved tribological and mechanical properties.

The wear and friction data have been made available in this article for the use of Al/FA/Gr hybrid composites in tribological applications.

Recent trends in material science show a considerable interest in the manufacturing of metal matrix composites to meet the stringent demands of lightweight, high strength and corrosion resistance. Aluminium is the popular matrix metal currently in vogue that can be reinforced with ceramic materials such as particulates to meet the desired property. The purpose of this paper is to fabricate hybrid metal matrix composites to improve the dry sliding wear resistance and to study of the effect of sliding speed, load and reinforcement (alumina and graphite) on wear properties, as well as its contact friction.

The present study addresses the dry sliding wear behaviour of Al‐Si10Mg alloy reinforced with 3, 6 and 9 wt% of alumina along with 3 wt% of graphite. Stir casting method was used to fabricate the composites. Mechanical properties such as hardness and tensile strength have been evaluated. A pin‐on‐disc wear test apparatus was used to evaluate the wear rate and coefficient of friction by varying the loads of 20, 30 and 40 N, sliding speeds of 1.5 m/s, 2.5 m/s and 3.5 m/s at a constant sliding distance of 2100 m.

Mechanical properties of hybrid metal matrix composites (HMMCs) have shown significant improvement. The wear rate and coefficient of friction for alloy and composites decreased with increase in sliding speed and increased with increase in applied load. Temperature rise during wearing process for monolithic alloy was larger than that of HMMCs and Al/9% Al₂O₃/3% Gr composite showing the minimum temperature rise.The worn surfaces of the composites were investigated using scanning electron microscope.

The paper shows that aluminium composites can improve strength and wear resistance.

HMMCs has proven to be useful in improving the dry sliding wear resistance.

It has been shown that circuit interconnects and various passive components can be fabricated on a variety of flexible substrates using the offset lithographic process. This paper reports on a feasibility study investigating the manufacture of voltaic cells deposited via offset lithography.

The Leclanché cell, an established battery chemistry, was chosen as an appropriate technology for adaptation to the offset lithographic process. Development of inks with appropriate rheological properties for lithographic printing was undertaken. Zinc and carbon electrodes were fabricated with silver‐based current collectors. Electrolyte composition was investigated along with separator materials.

Zinc and carbon‐based inks have been produced which result in deposited material appropriate for use as electrodes. A separator material soaked in electrolyte has been combined with these electrode structures and an MnO₂ paste to form a voltaic cell. A printed battery, made up of these voltaic cells, with a capacity greater than 8 mAh at 6 V has been produced.

The fabrication of voltaic cells via offset lithography facilitates the production of electronic systems with power sources provided by the same printing process. This paper provides information of interest to all those involved in the developing industry of printed and flexible electronics.

The purpose of this paper is to produce Al6061 metal matrix composites reinforced with silicon carbide (SiC) and graphite particulates and study their wear behavior and also to develop artificial neural network model to predict the mass loss of hybrid composites.

The hybrid composites were produced by using stir casting process. The experiments were conducted based on the central composite rotatable design matrix using pin‐on‐disc wear testing machine. The set of data collected from the experimental values were used to train a back propagation (BP) learning algorithm with one hidden layer network. In artificial neural network (ANN) training module, four input vectors were used in the construction of proposed network namely, weight percentage of SiC particles, weight percentage of graphite particles, applied load and sliding distance. Mass loss was the output to be obtained from the proposed network. After training process, the test data collected from the experimental values were used to check the accuracy of proposed ANN model.

The results show that the well trained one hidden layer network have smaller training errors and much better generalization performance and can be successfully used for the prediction of mass loss of hybrid aluminium metal matrix composites.

In this paper the ANN method was adopted to predict the mass loss of hybrid composites. It was found that artificial neural network can be successfully used for prediction of mass loss of composites.

In the current scenario, new materials are gaining popularity due to higher specific properties of strength and stiffness, increase in wear resistance, dimensional stability at higher temperature, etc. Subsequently, the need for precise machining has also been increased enormously. The purpose of this paper is to study the surface roughness during the turning of Al-10%SiC and Al-5%SiC-5%Gr composites under different cutting conditions.

Artificial neural network (ANN) has been effectively employed in solving problems with effortless computation in the areas such as fault diagnosis, process identification, property estimation, data smoothing and error filtering, product design and development, optimisation and estimation of activity coefficients. Response surface method is also used to analyse the problems involving a number of input parameters and their corresponding relationship between one or more measured dependent responses. Using Design Expert.8 evaluation software package, a simpler and more efficient statistical RSM model has been designed. RSM models are created by using 27 experimental data measurements obtained from different turning conditions of aluminium alloy composites.

In this work, the surface roughness during turning of Al-10%SiC and Al-5%SiC-5%Gr composites under different cutting conditions has been studied. The surface roughness value is proportional with the increase in feed rate and depth of cut while inversely proportional with the cutting speed. In all turning conditions, Al-10%SiC composite has lower surface roughness values than Al-5%SiC-5%Gr hybrid composite. An ANN and response surface models have been developed to predict the surface roughness of machined surface. The experimental results concur well with predicted models.

In the present trend, new materials are gaining popularity due to higher specific properties of strength and stiffness, increase in wear resistance, dimensional stability at higher temperature, etc. Subsequently, the need for precise machining has also been increased enormously. In this work, the surface roughness during turning of Al-10%SiC and Al-5%SiC-5%Gr composites under different cutting conditions has been studied.