Quantitative studies on wear behavior of Al–(Al2O3–SiC–C) composite prepared with in situ ceramic composite developed from colliery waste

The present study reports the influence of wear parameters like sliding speed (V), applied load (L) and sliding distance (S) on the dry sliding wear behavior of aluminum metal matrix composites prepared with thermally treated colliery shale (CS) material, a waste from coal mine. The design of experiment approach is employed to acquire data in a controlled way using Taguchi method. A pin-on-disc apparatus is used to conduct the dry sliding wear tests. Orthogonal array and analyses of variance are employed to investigate the wear behavior of the developed composite. For comparison purpose, similar tests are conducted on the composites made of Al–Al2O3 and Al–Al2O3–SiC. Regression equations are obtained using experimental data, interrelated operating variables such as S, V, and L on weight loss, coefficient of friction, and cumulative wear of the composites. Confirmation tests are conducted to verify the experimental results. The worn out surfaces are examined with scanning electron microscopy to understand the wear mechanism. The in situ conversion of SiC from SiO2 in the vicinity of Al2O3 and the presence of carbon in the form of graphite have helped to improve the wear resistance of the developed Al–CS composite.