Characterizing sliding wear behavior of A1100/AlFe (p) composites produced via repeated fold-forging and annealing

Yu-Fong Tseng; Chao-Hwa Liu; Ching-Bin Lin

doi:10.1515/ijmr-2021-8412

Article

Characterizing sliding wear behavior of A1100/AlFe (p) composites produced via repeated fold-forging and annealing

Yu-Fong Tseng , Chao-Hwa Liu and Ching-Bin Lin

Published/Copyright: September 27, 2024

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From the journal International Journal of Materials Research Volume 115 Issue 10

Abstract

Aluminum matrix/aluminum-iron intermetallic composite materials pose challenges in plastic processing due to the susceptibility of hard intermetallic compound particles to fracture. This study introduces a novel fabrication method involving pure iron mesh, hot-dip aluminum plating, and solidification. Through ten consecutive folding, forging, and intermediate annealing cycles, aluminum matrix and iron undergo diffusion, leading to the formation of Fe₂Al₅ and FeAl₃ interface reaction layers, as confirmed by X-ray diffraction analysis. Subsequent forging cycles cause the breakage or detachment of Fe₂Al₅ and FeAl₃ particles from the interface, resulting in the formation of large-sized Fe₂Al₅ and small-sized Fe₂Al₅ intermetallic particles. FeAl₃ intermetallic particles are observed via microscopic examination. These particles can be uniformly dispersed within the aluminum matrix through plastic flow, enabling the successful fabrication of A1100/Fe₂Al₅ and AlFe₃ composite sheets. Furthermore, the study investigates the impact of intermetallic compound content, sliding speed, and forward load on the dry sliding wear of A1100/FeAl composites. It is found that Fe₂Al₅ and AlFe₃ intermetallic compound particles effectively mitigate adhesive wear, plowing, and oxidative wear of the composites. With an AlFe intermetallic compound content of 4.3 wt.%, the volume wear rate remains low under conditions corresponding to PV = 56.652 (equivalent to a normal load of 19.6 kPa and a sliding speed of 2.87 m s⁻¹).

Keywords: Composites; Intermetallic; Morphology; Wear

Corresponding author: Ching-Bin Lin, Department of Mechanical and Electromechanical Engineering, TamKang University, Tamsui District, New Taipei City, Taiwan, E-mail: cblin@mail.tku.edu.tw

Acknowledgments

We would like to thank professor Adel Fathy Meselhy Ibrahim for providing valuable information on using neural network models for predicting the wear properties of composite materials.

Research ethics: Not applicable.
Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission. Chao-Hwa Liu: conceptualization; investigation; write-review and editing. Ching-Bin Lin: methodology; writing-orginal draft; experimental design. The Yu-Fong Tseng: data curation; formal analysis; resources.
Use of Large Language Models, AI and Machine Learning Tools: Not applicable.
Conflict of interest: The authors state no conflict of interest.
Research funding: Not applicable.
Data availability: Not applicable.

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Received: 2021-06-14

Accepted: 2024-06-04

Published Online: 2024-09-27

Published in Print: 2024-10-28

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Articles in the same Issue

https://doi.org/10.1515/ijmr-2021-8412

Keywords for this article

Composites; Intermetallic; Morphology; Wear