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173
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MICROSTRUCTURE
COMPOSITES*
AND WEAR
OF CAST
(Al-Si
ALLOY)-GRAPHITE
(Council
of Scientific
and Industrial
Research),
Bhopal
T. R. RAMACHANDRAN
Indian
Institute
of Technology,
Kanpur
208016
(U.P.)
(India)
Summary
Graphite-particle-dispersed
Al-Si alloys have potential for a variety of
antifriction
applications.
In the present investigation,
two Al-Si
alloys
(LM13
of near eutectic
and LM30 of hypereutectic
composition)
were
chosen as matrix alloys and composites were prepared by casting. Composites and matrix alloys were heat treated to produce different morphologies
of silicon ranging from plate-like in die-cast alloys to near spherical in heattreated alloys.
Wear tests were conducted,
under both dry and partially lubricated
conditions,
with SAE30 oil on a pin-on-disc wear test apparatus, against a
rotating
steel (EN25)
counterface.
In partially lubricated
wear tests, the
sliding velocity V was varied from 1.4 to 4.6 m s- and the applied pressure
P from 1 .O to 5 .O MPa. P-V limits of all matrix alloys and composites with
different
microstructures
were evaluated.
Heat-treated
composites
were
found to possess superior wear properties (wear rate, seizure resistance and
P-V limits) as compared
with those of die-cast composites
and matrix
alloys. Worn surfaces of heat-treated
composites showed the presence of a
graphite film while those of die-cast alloys and composites showed surface
fracture.
The role of graphite particle dispersion and the morphology
of
silicon on the sliding we::r behaviour is discussed.
1. Introduction
Al-S1 alloys are extensively
used in tribological
applications
such as
pistons (and in some cases as cylinder liners) in internal combustion engines.
Although Al-Si alloys meet many of the requirements
for such applications,
their poor resistance
to seizure makes them vulnerable under poor lubricating conditions.
To overcome
this problem,
several investigators
have
*Paper presented at the International
U.S.A., April 8 - 14, 1989.
Conference
on Wear of Materials,
0043-1648/89/$3.50
@ Elsevier Sequoia/Printed
Denver,
CO,
in The Netherlands
174
2. Experimental
details
175
TABLE
Chemical
Alloy
LM13
LM30
compositions
Elementa
of LM13
and LM30
alloys
(wt.%)
Si
cu
11.0
17.0
1.0
4.5
1.0
0.5
aIn addition,
the melt was alloyed
posites. The Al-Si eutectic contains
Ni
Fe
Mn
Al
1.5
0.1
0.8
0.3
0.5
0.1
Balance
Balance
the preparation
of the com-
End loading
by hydraulic
cylinder
Force
transducer
Fig. 1. Schematic
representation
of the Cameron-Plint
pin-on-disc
176
Pressure on the specimen was increased in steps of 0.5 MPa until the specimen seized before a sliding distance of 500 m was reached. The onset of
seizure was signalled by a sudden increase in test pin temperatures followed
by vibration and noise from the disc-pin assembly.
2.3.2. Lubricated sliding wear
Partially lubricated we.3 tests were performed on the same apparatus
but using a modified procedure. In this case, the steel disc (EN25) was first
dipped in SAE30 lubricating oil. The excess oil was spun off the disc by
rotating it for 5 s at 640 rev mm
. -l before the commencement of the actual
test.
All lubricated wear tests were carried out at sliding distances up to
2500 m. Disc rotation was first fixed at 330 rev min (corresponding sliding
velocity, 1.38 m s-i). A pressure of 1 .O MPa was applied to the specimen and
the test was run for 2500 m. If the sample did not seize at this pressure the
disc was removed, cleaned, reimmersed in SAE30 oil, excess oil removed and
the applied pressure was increased in steps of 0.5 MPa. By this means a
critical applied pressure was determined where seizure occurred within a
sliding distance of 2500 m.
2.4. Microscopy
3. Results
3.1. Microstructure
The microstructures of diecast (Al-Si (LM13) alloy)-graphite particle
composites are shown in Fig. 2. Figure 2(a) shows the distribution of graphite particles in the Al-Si alloy matrix while Fig. 2(b) shows the matrix
mi~rost~cture. The microst~cture immedia~ly su~ounding the dispersed
graphite particles (Fig. 2(c)) shows that the graphite particle was pushed into
the last freezing eutectic liquid. The microstructure of the Al-Si (LM13)
alloy matrix in the heat-treated condition is shown in Fig. 3. Clearly, the
heat treatment altered the morphology of the eutectic silicon from plate-like
to nearly spherical. The microstructure of the LM30-graphite particle
composite in the die-cast condition is shown in Fig. 4(a). Graphite particles,
primary silicon and eutectic silicon can be clearly seen. A typical matrix
microstructure of the heat-treated LM30 alloy (Fig, 4(b)) shows similar
changes in the morphology of eutectic silicon as in the case of LM13 alloy.
(c)
Fig. 2. Microstructure
of AI-S1 (LM13)
alloy-graphite
particle
composites
in the diecast condition
showing (a) the distribution
of graphite particles,
(b) a magnified view of
the matrix
microstructure
and (c) matrix microstructure
in the vicinity
of the graphite
particle.
Fig. 3. Microstructure
of Al-Si
(LM13)
alloy matrix
in the heat-treated
condition.
(a)
(h)
Fig. 4. (a) Microstructure
of LM30-~graphite
composite
in the die-cast condition
showing
both primary and eutectic silicon, graphite particles and primary aluminium
(P, primary
silicon; E, eutectic silicon; G, graphite).
(b) Microstructure
of LM30 alloy matrix in the
heat-treated
condition.
The change in the shape of eutectic silicon from needle-like
to
nearly spherical should be noted.
ALMl3
OLM30
+ Seizure
Pressure, MPo
Pressure.
MPo
Fig. 5. Effect
of applied
pressure
alloys.
Fig. 6. Effect of applied pressure on the dry sliding wear rates of LM13 alloy and LMl3
graphite composites
in the die-cast and heat-treated conditi.ons.
directly proportional
to the applied pressure. For instance, the wear rate of
LM13 alloy was increased from 1.0 X lo--l2 to 2.5 x lo-l2 m3 m-l when the
applied pressure was increased from 1.0 to 1.5 MPa. Beyond this applied
pressure (i.e. at 2.0 MPa), a drastic increase in wear rate from 2.5 X lo-l2 to
17 X lo-l2
m3 m- was observed. The specimens were also seized at this
pressure before a sliding distance of 500 m was reached. By constrast, there
was no such drastic increase in the wear of LM30 alloy with increase in
179
applied pressure. Secondly, the LM30 alloy seized at a much higher applied
pressure of 5.0 MPa.
Figure 6 shows the effect of graphite particle dispersion and heat
treatment on the wear rate of LM13 alloy at various applied pressures. Of
the four types of samples tested, the heat-treated LM13 graphite composite
showed lowest wear rates at all applied pressures. Secondly,
the seizure
resistance (i.e. tie minimum pressure at which the sample seized) is the
highest for the heat-treated LM13 graphite composite. The seizure resistance
of LM30 alloy was not influenced by heat treatment and/or graphite particle
dispersion. However, heat-treated LM30-graphite
composites
showed the
lowest wear rates at all applied pressures (Fig. 7).
4MPa
3MPa
2 M30
_I
0
Pressure,
Fig. 7. Effect
in the die-cast
60
T#me, seconds
MPa
Fig. 8. Temperature
20
wear of LM30
alloy
and composites
alloy.
180
TABLE
Maximum
temperature
Applied
pressure
Temperature
LM13
die
cast
WPa)
1.0
1.5
44
50
2.0
2.5
3.0
3.5
4.0
5.0
--___
(C)
LM13
(HT)
LM13
graphite
LM13
graphite
(HT)
LM30
die
cast
LM30
WT)
36
39
_._.__
LM30
graphite
(HTj
47
3s
80
-.
7-I
86
44
60
154a
98
150a
72
98
90
106
80
._
_
-
144
150a
118
108
130
1 5oa
136
21Ba
_____.
LM30
graphite
-_._..
82
100
130
158a
116
1IO
_.
162
206a
I18
160
aSeizure.
TABLE
Coefficients
of friction
Alloy
Coefficient
0.125
0.119
0.103
0.059
0.172
0.143
0.140
0.071
LM13 (HT)
LM13-graphite
(HT)
LM13-graphite
LM30 (die cast)
LM30 (HT)
LM30-graphite
LMSO-graphite
(HT)
of friction
(b)
(a)
Fig. 9. Scanning
electron
tion and (b) heat-treated
micrographs
condition.
of LM13
alloy:
(a) die-cast
condi-
(b)
(a)
Fig.
site:
of worn surfaces
10. Scanning
electron
(a) die-cast condition
(a)
Fig. 11. Scanning
electron
LMSO-graphite
composites
micrographs
of worn surfaces
and (b) heat-treated
condition.
of LM13
alloy-graphite
compo-
(b)
micrographs
of worn
in die-cast condition.
surfaces
of
(a) LM30
alloy
and
(b)
difference
between the two wear surfaces. In both cases, there were long
grooves and patches of severely damaged regions. In contrast, wear surfaces
of heat-treated
L~30-~phite
eomposites (Fig. 12(a)) showed no evidence
of severely damaged regions; the number of grooves was much less ana the
surface showed the presence of graphite film. Figure 12(b) is a carbon X-ray
Fig. 12. (a) Scanning dectron micrograph of worn surface of heat-treated L~30-~aphite
composite. (b) X-ray dot map of carbon corresponding to (a).
Fig. 13. Scanning electron micrograph of LM13 debris obtained at low (1.0 MPa) applied
pressure.
Fig. 14. (a) Scanning electron micrograph of die-cast LM13 alloy wear debris at high
applied pressures (2.0 MPa). (b) Magnified view of a typical flake-type debris particle
showing cracks.
(a)
(b)
(a)
(b)
Fig. 16. (a) Scanning electron micrograph of a large silicon wear debris particle from
LM30 alloy (applied pressure, 4 MPa). (b) Silicon X-ray dot map corresponding to (a).
184
composites, the debris also consisted of large faceted silicon (size, 70 pm)
particles in addition to flake-type debris. One such silicon debris particle is
shown in Fig. 16(a). Figure 16(b) is a silicon dot map corresponding to
Fig. 16(a).
3.3. Partially lubricated wear
P-V limits of LM13 alloy and LM13 alloy-graphite composites in
die-cast and heat-treated conditions are shown in Fig. 17 while the corresponding curves for LM30 alloy and composites are shown in Fig. 18. Each
point in any one curve represents the minimum applied pressure at which the
specimen begins to seize at a particular sliding velocity (speed). At lower
sliding velocities, the specimens were able to withstand higher applied pressures. With an increase in sliding velocity, however, there was a progressive
decrease in the limiting value of the applied pressure. It can be seen from
Fig. 17 that the maximum P-V limits are obtained for the LM13graphite
composites in the heat-treated condition. Similarly, the P-V limits of heattreated LM30graphite composites were found to be superior to those of the
other LM30-based alloys. Therefore the results of partially lubricated sliding
wear studies appear to be in good agreement with the results of the dry
wear tests. In both cases, the heat-treated composites showed optimum
properties.
1
12
12r-
l LMl3CtiT)
A LM 13-Grophlte
2 _
0 LM 13-Graphfte
(HT)
[II LM 30-Graphrte
J
5
Sltdmg
velocity,
m/s
(HT)
Shdmg
velocity,
I
:
m/s
4. Discussion
In the Al-Si alloy system, the eutectic forms at 12.6 wt.% Si [14]. The
microstructure of LM13 alloy (containing 11.0 wt.% Si), solidified in a
metallic mould, consists of primary aluminium dendrites with an average
dendrite arm spacing (i.e. centre-tocentre distance between neighbouring
185
TABLE 4
Tensile strengths of aluminium alloys and composites
Alloy
Ultimate tensile
strength (MPa)
180
280
130
190
140
LMSO-graphite
LMSO-graphite (HT)
220
98
160
186
reduced from 180 to 130 MPa, while that of LM30 alloy was reduced from
140 to 98 MPa from the 3.0 wt.% dispersion of graphite partiefes (Table 4).
This fess in strength offsets the positive effect of dispersed solid lubricant
in reducing friction and shear stresses. In addition to graphite, the sharpedged silicon phase also acts as a stress riser. The stress concentration can
be lowered by changing the morphology of silicon from plate shaped to
spherical.
The results of the present study show that, under both dry and Iubricated sliding wear conditions, superior wear properties were generalfy
observed in the case of heat-treated composites, It is interesting to note
that the worn surfaces of heat-treated composites showed graphite film on
the sliding surfaces whereas no such graphite film was detected on the worn
surfaces of die-cast composites. The combined effect of the increase in
tensile strength and the reduction in metal-to-metal contact (i.e. between
AI-Si alloy and steel) due to the presence of graphite film on the mating
surface might have resulted in the observed improvements in the friction and
wear properties of the heat-treated composites.
5, Conclusions
(I) The presence of dispersed graphite particles and the morphology
of the silicon phase were found to influence the friction and wear behaviour
of the (Al-% ploys-~phite
composites.
(2) For the LM13 alloys and composites, the heat-treated composites
showed least wear and maximum resistance to seizure. Similarly, the heattreated LM30 alloy-graphite composites showed optimum wear properties.
(3) The worn surface of the heat-treated composites showed the presence of a graphite film whereas those of the die-cast alloys and composites
showed a considerable amount of surface cracks.
(4) The coefficients of friction of the LMl3 and LM30 alloys were
reduced by more than 50% because of graphite particle dispersion and heat
treatment.
(5) The P-V limits of the heat-treated composites under partially
lubricated conditions were found to be higher than those of the other
materials.
Two of the authors (S.D. and S.V.P.) are grateful to Dr. R. Kumar,
Director RRL, Bhopal, for his encouragement and permission to publish
this paper.
187
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