Interface modification and impact abrasive wear behavior of ZTA particle-reinforced iron-matrix composite

This paper investigates the effect of interface modification on the microstructure and on impact abrasive wear behavior of zirconia toughened alumina particle (ZTAp) -reinforced iron-matrix composites. In order to improve the interface bonding between ZTAp and iron matrix, ZTAp was wrapped with Ti–Ni–Cu mixed powder (Ti–Ni–Cu@ZTAp), and then the Ti–Ni–Cu@ZTAp/Fe45 composite (modified composite) was prepared by vacuum sintering. The results show that a metallurgical bonding interface layer of 15–25 μm thickness between the modified ZTAp and the iron matrix is formed, which improves their interface bonding. The modified composite presents better wear resistance compared with the unmodified composite and the relative wear resistance of the modified composite reaches the maximum value of 1.88 at 2J. In addition to good bonding, the interface layer with medium hardness and modulus reduces difference between the modified ZTAp and the iron matrix in terms of mechanical properties and behaviors under impact of abrasives, which can play a force transition role and release stress through its plastic deformation. Therefore, the modified ZTAp is more difficult to fall off from the matrix and has a longer protective effect on the matrix. •A novel interface modified composite is prepared by vacuum sintering.•Elements diffusion and new phase formation improve the interfacial bonding.•The transition effect of the interface layer reduces stress concentration.•Interface modification increases the wear resistance of the composites by 66–88%.