Materials and Design 31 (2010) 18041812

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Materials and Design

journal homepage: www.elsevier.com/locate/matdes

Effect of addition of graphite particulates on the wear behaviour

in aluminiumsilicon carbidegraphite composites
S. Suresha *, B.K. Sridhara
Department of Mechanical Engineering, The National Institute of Engineering, Mysore 570 008, Karnataka, India

a r t i c l e

i n f o

Article history:
Received 23 August 2009
Accepted 7 November 2009
Available online 12 November 2009
Keywords:
Hybrid composites
Design of experiments
Interaction

a b s t r a c t
Aluminium matrix composites with multiple reinforcements (hybrid AMCs) are nding increased applications because of improved mechanical and tribological properties and hence are better substitutes for single reinforced composites. Few investigations have been reported on the tribological behaviour of these
composites with % reinforcement above 10%. The present study focuses on the inuence of addition of
graphite (Gr) particulates as a second reinforcement on the tribological behaviour of aluminium matrix
composites reinforced with silicon carbide (SiC) particulates. Dry sliding wear tests have been performed
to study the inuence of Gr particulates, load, sliding speed and sliding distance on the wear of hybrid
composite specimens with combined % reinforcement of 2.5%, 5%, 7.5% and 10% with equal weight % of
SiC and Gr particulates. Experiments are also conducted on composites with % reinforcement of SiC similar
to hybrid composites for the sake of comparison. Parametric studies based on design of experiments (DOE)
techniques indicate that the wear of hybrid composites decreases from 0.0234 g to 0.0221 g as the % reinforcement increases from 3% to 7.5%. But the wear has a tendency to increase beyond % reinforcement of
7.5% as its value is 0.0225 g at.% reinforcement of 10%. This trend is absent in case of composites reinforced
with SiC alone. The values of wear of these composites are 0.0323 g, 0.0252 g and 0.0223 g, respectively,
at.% reinforcement of 3%, 7.5% and 10% clearly indicating that hybrid composites exhibit better wear characteristics compared to composites reinforced with SiC alone. Load and sliding distance show a positive
inuence on wear implying increase of wear with increase of either load or sliding distance or both.
Whereas speed shows a negative inuence on wear indicating decrease of wear with increase of speed.
Interactions among load, sliding speed and sliding distance are noticed in hybrid composites and this
may be attributed to the addition of Gr particulates. Such interactions are not present in composite
reinforced with SiC alone. Mathematical models are formulated to predict the wear of the composites.
2009 Elsevier Ltd. All rights reserved.

1. Introduction
Metal matrix composites are evolved as newer materials as an
out come of a steadily growing efforts to cater to the increasing demand for lightweight, inexpensive, energy saving, stiff and strong
materials in aircraft, space, defense and automotive applications.
Aluminium matrix composites (AMCs) are emerging as promising
materials in this direction [1,2]. AMCs reinforced with SiC particulates are known for higher modulus, strength and wear resistance
compared to conventional alloys. Garcia et al. have observed that
the specic wear rate of AA6061-SiC composites decreases with increase in volume fraction and size of reinforcement [2]. Das et al.
have discussed on formation of mechanically mixed layer (MML)
consisting of debris and smeared and fragmented SiC particles.
SiC needles in MML and in the subsurface region are fragmented
into ner particles thus demonstrating the occurrence of subsur* Corresponding author. Tel.: +91 9448800649; fax: +91 0821 2485802.
E-mail address: surs.mar69@yahoo.com (S. Suresha).
0261-3069/$ - see front matter 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2009.11.015

face damage during abrasive wear of LM13-SiC composites [3].

Sahin et al. have noticed signicant increase in wear resistance
up to 10% addition of SiC and a stable value between 10% and
55% for AlSiC composites produced by vacuum inltration [4].
Both mechanical strength and wear resistance of composites
increase by adding SiC particulates to the matrix alloy. But the consequent increase in hardness makes the machining difcult. Thus,
it is essential to look for ways to retain the advantageous inuence
of SiC and simultaneously attending the problem of machining of
composites reinforced with SiC. Graphite particulates come handy
in this direction, the addition of which improves the machining as
well as wear resistance of AlSiC composites. AlSiC composites
reinforced with Gr particulates are referred as AlSiCGr hybrid
composites. The outcome of some investigations on such hybrid
composites are briefed in the next few lines.
Rohatgi et al. have reported that the reduction in friction coefcient of Al10SiC6Gr is due to the combination of increase in
bulk mechanical properties as a result of addition of SiC and formation of graphite lm [5]. Ted Guo et al. have observed that wear of

1805

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

Al10SiC28Gr increases up to 5% Gr because of reduced fracture

toughness and then decreases due to the formation of thick solid
lubricant lm which overrides the effect of fracture toughness
[6]. Riahi et al. have focused upon the inuence of tribo layer of
MML containing primarily Gr on wear of Al10SiC4Gr hybrid
composites [7]. The investigations of Basavarajappa et al. on Al
15SiC3Gr composites have indicated that the degree of subsurface
deformation and thereby the wear rate in graphite composites is
less than that of graphite free composites [8]. These investigations
emphasize that the use of multiple reinforcements in aluminium
matrix hybrid composites yield better tribological properties.
However, efforts are scarce on parametric studies on the tribological behaviour of aluminium matrix hybrid composites. In this
context, an attempt is made here to study the inuence of graphite
particulates, load, % reinforcement, sliding speed and sliding distance on the tribological behaviour of AlSiCGr hybrid
composites.

Table 2
Details of reinforcements.
Reinforcement

Hardness (GPa)

Grain size (lm)

Density (g/cm3)

SiC
Gr

24.529
0.25

1020
7080

3.22
2.092.23

Table 3
Details of AlSiCGr hybrid composites.
AlSiCGr hybrid composites
Combined % reinforcement
SiC
Gr
Hardness, BHN

0.00
0.00
0.00
67

2.50
1.25
1.25
72

5.00
2.50
2.50
70

7.50
3.75
3.75
68

10.0
05.0
05.0
66

Table 4
Details of AlSiC composites.

2. Experiments

AlSiC composites

AlSiCGr and AlSiC composites required for the investigation

are fabricated by stir casting [9]. LM25 is used as the matrix alloy
and details of its composition is given in Table 1. Table 2 provides
the details of SiC and Gr particulates which are used as reinforcements. Table 3 gives the details of hybrid composites. AlSiCGr
hybrid composites with combined weight % reinforcement of
2.5%, 5%, 7.5% and 10% are used. In each of these composite as seen
in Table 3, % reinforcement of each of SiC and Gr is equal. The hardness values of these composites are also indicated in the table.
There is reduction in hardness with increase in % reinforcement
and this is due to the addition of Gr. Similar details of AlSiC composites are given in Table 4. It can be observed that hardness increases with % reinforcement of SiC [14]. The as cast composites
are of 10 mm diameter, 50 mm length from which Wear test specimens of length 35 mm and 8 mm diameter are machined. The end
of the specimens are polished with abrasive paper of grade 600 and
followed by grade 1000. Dry sliding tests are carried out as per
ASTM G99-95a test standards on pin-on-disc equipment the disc
of which is of EN31 steel with surface roughness, Ra 0.1. The pins
are cleaned with acetone and weighed before and after testing to
an accuracy of 0.0001 g to determine the amount of wear. The sliding end of the pin and the disc surfaces are cleaned with acetone
before testing.
The experiments are designed based on central composites design (CCD) scheme of design of experiments (DOE) [10]. CCD is very
effective experimental technique in studies involving large number
of factors. A set of experimental design that can look at K factors in
n observations with each factor at two levels is called two level
factorial design, which can prove good and efcient when a linear
relationship prevails between the factors and the response. Three
or higher level experiments are mandatory when nonlinear
relationship exists, which ends up with increased cost and time
of testing. CCD is the most efcient method, alternative to 3k or
more factorial experimental designs. CCD can be used to study factors at ve levels in reduced number of tests [1013].
Load, % reinforcement, sliding speed and sliding distance are the
factors which inuence the tribological behaviour of a composite.
Table 5 provides the experimental plan and the experimental
results obtained. Wear in terms of weight loss is the measured

Table 1
Chemical composition of the matrix alloy LM25.
Element

Si

Mg

Fe

Cu

Cr

Zn

Ni

Mn

Content %

7.1

0.3

0.3

<0.012

0.004

0.002

0.01

0.28

% reinforcement of SiC
Hardness, BHN

0.00
67

2.50
72

5.00
76

7.50
79

10.0
81

response used to evaluate the tribological behaviour of AlSiC

composite and AlSiCGr hybrid composites. Table 6 shows the
factors and their levels employed in the experiments.
3. Analysis of results
The experimental results are analyzed with the help of MINITAB14, a statistical analysis software, which is widely used in
many elds of engineering research. Results are analyzed by ANOVA with a condence limit of 95% or P-value of 0.05. This implies
any factor with P-value equal to or <0.05 is signicant. The significance of a factor can be conrmed by the main effects plot and
normal probability plot. The inuence of % reinforcement on wear
relative to load, sliding speed and sliding distance are discussed
with the help of respective contour plots [11,13].
ANOVA results of AlSiC composites are given in Table 7. Second and higher order interactions are not considered for ANOVA.
The quadratic terms of the factors are included in the analysis in
order to incorporate the results of the composite part of CCD which
may have curvilinear effect on the response [11]. It can be observed
that the % reinforcement (A), sliding speed (B), load (C) and sliding
distance (D) are signicant as the P-value for these is <0.05. The %
contribution of each of these terms is calculated by dividing their
respective sum of squares value by the total sum of squares and
these values are indicated in Table 8. Fig. 1 shows the main effect
plot of the effects of factors on wear of AlSiC composites.
Fig. 2 shows the normal probability plot of standardized effects
of factors on wear of AlSiC composites. The observation indicates
that % reinforcement and sliding speed have negative effect on
wear as they are on the left of the normal probability line indicating any increase of their value from low level to high level results
in reduction of wear. Other investigations, based on one factor- ata-time experiments, have revealed a little positive effect of sliding
speed on wear of AlSiC composites in the range considered in the
present work [1]. The effect of other two factors, load and sliding
distance is positive on wear as they lie on the right to the line.
The effect of sliding distance is more predominant as evident from
Figs. 1 and 2. The effect of load is less than sliding distance as it is
close to the line. These are also evident from the values of % contribution of factors as in Table 8. It can be observed that the value of %
contribution is the highest for sliding distance followed by sliding
speed, load and % reinforcement.

1806

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

Table 5
Details of test combinations (tc) in coded and actual values of factors and corresponding experimental results.
tc

% Reinforcement A

Speed B

Load C

Dist D

Wear AlSiC (g)

Wear AlSiCGr (g)

1
a
b
ab
c
ac
bc
abc
d
ad
bd
abd
cd
acd
bcd
abcd
aa
+aa
ab
+ab
ac
+ac
ad
+ad
Zero
Zero
Zero

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
0
0
0
0
0
0
0
0
0

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
2
2
0
0
0
0
0
0
0

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
2
2
0
0
0
0
0

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
2
2
0
0
0

2.5
7.5
2.5
7.5
2.5
7.5
2.5
7.5
2.5
7.5
2.5
7.5
2.5
7.5
2.5
7.5
0
10
5
5
5
5
5
5
5
5
5

0.8
0.8
1.6
1.6
0.8
0.8
1.6
1.6
0.8
0.8
1.6
1.6
0.8
0.8
1.6
1.6
1.2
1.2
0.4
2.0
1.2
1.2
1.2
1.2
1.2
1.2
1.2

30
30
30
30
60
60
60
60
30
30
30
30
60
60
60
60
45
45
45
45
15
75
45
45
45
45
45

800
800
800
800
800
800
800
800
1600
1600
1600
1600
1600
1600
1600
1600
1200
1200
1200
1200
1200
1200
400
2000
1200
1200
1200

0.0088
0.0069
0.0045
0.0039
0.0115
0.0091
0.0085
0.0053
0.0211
0.0156
0.0115
0.0088
0.0240
0.0187
0.0226
0.0142
0.0119
0.0108
0.0171
0.0085
0.0071
0.0152
0.0024
0.0198
0.0133
0.0076
0.0093

0.0081
0.0063
0.0041
0.0026
0.0090
0.0070
0.0060
0.0049
0.0165
0.0149
0.0098
0.0085
0.0188
0.0176
0.0156
0.0134
0.0119
0.0081
0.0127
0.0078
0.0055
0.0100
0.0020
0.0196
0.0087
0.0084
0.0089

Table 6
Factors and their levels in CCD experimental plan.
Factors

Levels

Reinforcement, %
Sliding speed, m/s
Load, N
Sliding distance, m

A
B
C
D

2

1

0
0.4
15
400

2.5
0.8
30
800

5
1.2
45
1200

7.5
1.6
60
1600

10
2.0
75
2000

Table 7
ANOVA results of wear of AlSiC composites. Analysis of variance for W(AlSiC), using
adjusted SS for tests.
Source

DF

Seq SS

Adj SS

Adj MS

A
B
AB
C
AC
BC
D
AD
BD
CD
ACD
AA
BB
CC
DD
Error
Total

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
11
26

0.0000432
0.0001197
0.0000000
0.0001000
0.0000046
0.0000076
0.0005302
0.0000119
0.0000042
0.0000093
0.0000004
0.0000004
0.0000092
0.0000015
0.0000027
0.0000454
0.0008902

0.0000432
0.0001197
0.0000000
0.0001000
0.0000046
0.0000076
0.0005302
0.0000119
0.0000042
0.0000093
0.0000004
0.0000037
0.0000130
0.0000029
0.0000027
0.0000454

0.0000432
0.0001197
0.0000000
0.0001000
0.0000046
0.0000076
0.0005302
0.0000119
0.0000042
0.0000093
0.0000004
0.0000037
0.0000130
0.0000029
0.0000027
0.0000041

10.47
29.02
0.00
24.26
1.12
1.83
128.54
2.89
1.02
2.26
0.09
0.91
3.16
0.70
0.66

0.008
0.000
0.981
0.000
0.312
0.203
0.000
0.117
0.334
0.161
0.773
0.361
0.103
0.420
0.435

S = 0.00203090, R-Sq = 94.90%, R-Sq(adj) = 87.95%.

Table 8
Percentage contribution of signicant factors affecting wear of AlSiC composites.
Factor

Error and others

4.85

13.45

11.23

59.56

10.91

ANOVA is also carried out on experimental results of

AlSiCGr hybrid composites. The main effect plot of the effects
of factors on wear of AlSiCGr hybrid composites is shown in
Fig. 3. Fig. 4 shows the normal probability plot of the effects
offactors and their interactions on wear of AlSiCGr hybrid
composites. The effect of factors AD is similar as in AlSiC composites. Apart from the factors AD, other terms like BC, BD, CD,
A  A, B  B and D  D are also signicant. The % contribution of
these terms is indicated in Table 9. There are interactions among
sliding speed, load and sliding distance and these may be attributed to the inclusion of Gr particulates in AlSiCGr hybrid composites. Other investigations, based on one factor-at-a-time
experiments, have revealed no effect of sliding speed on wear
of AlSiCGr hybrid composites in the range considered in the
present work [8].
The increase of sliding speed results in formation of a mechanically mixed tribo layer at a faster rate and thus reducing wear by
covering more area of contact. Increase in % reinforcement facilitates availability of more quantity of SiC and Gr for the formation
of tribo layer. This is evidenced by smear of very ne particles of
reinforcements over the disc surface during testing. Any increase
of load tries to weaken the tribo layer due to increase of pressure
over the tribo layer and consequent reduction of area covered by
the layer resulting in increase of wear. Wear increases with sliding
distance because of exposure of sliding end of the pin for more
duration of time for any values of % reinforcement, sliding speed
and load.
Mathematical models to predict wear are formulated by response surface regression analysis. Response surface and corresponding contour plots give wider insight to understand any
problem in general, and to optimize the factors inuencing the response in particular [11,13]. Table 10 shows the results of response
surface regression analysis for AlSiC composites. The regression
model in terms of coded values is represented by Eq. (1). Table
11 shows the results of response surface regression analysis for
AlSiCGr hybrid composites. The regression model in terms of
coded values is represented by Eq. (2). The adequacy of the model
can be checked by normal probability plot of residuals and the plot

1807

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

Main Effects Plot for wear of Al-SiC composites

% Reinforcement

Sliding speed, m/s

0.020

Mean of Wear(Al-SiC), g

0.015
0.010
0.005
0.000
0.0

2.5

5.0
Load, N

7.5

10.0

0.4

0.8
1.2
1.6
Sliding distance, m

2.0

15

30

45

60

75

400

800

2000

0.020
0.015
0.010
0.005
0.000
1200

1600

Fig. 1. Main effect plot of effects of factors on wear of AlSiC composites.

Normal Probability Plot of the Standardized Effects

(response is wear(Al-SiC), Alpha = .05)
99

95
90

Percent

80
70
60
50
40
30
20
A

10
5

Effect Type
Not Significant
Significant

1
-5.0

-2.5

0.0

2.5

5.0

7.5

10.0

12.5

Standardized Effect
Fig. 2. Normal probability plot of effects of factors on wear of AlSiC composites.

of residuals versus t [11,13]. Figs. 5 and 6, respectively, show the

plot of residual versus tted values of the response for AlSiC
composites and AlSiCGr hybrid composites. It can be seen in
the plots that the points are randomly scattered without forming
any particular pattern and there by evidencing the model
adequacy.

0:004263D 0:000416A  A 0:000478B  B

0:000616D  D 0:000519B  C  0:000481B  D
0:000619C  D

Here,

A a  5=2:5;

W 0:010067  0:001342A  0:002233B 0:002042C

0:004700D

W 0:008667  0:000846A  0:001796B 0:001271C

B b  1:2=0:4;

C c  45=15;

D d  1200=400
AD are coded values and ad are actual values of factors.

Here,

A a  5=2:5; B b  1:2=0:4;
D d  1200=400

C c  45=15;

AD are coded values and ad are actual values of factors.

4. Discussions
Contour plots are plots of constant wear and they employ a
combination of any two factors. Overlaid contour plots are conve-

1808

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

Main Effects Plot for wear of Al-SiC-Gr hybrid composites

% Reinforcement

Sliding speed, m/s

0.020
0.015

Mean of Wear, g

0.010
0.005
0.000
0.0

2.5

5.0
Load, N

7.5

10.0

0.4

0.8
1.2
1.6
Sliding distance, m

15

30

45

60

75

400

800

0.020

2.0

0.015
0.010
0.005
0.000
1200

1600

2000

Fig. 3. Main effect plot of effects of factors on wear of AlSiCGr hybrid composites.

Normal Probability Plot of the Standardized Effects

(response is wear(Al-SiC-Gr), Alpha = .05)
99

95
90

C
D*D
CD
B*B
BC
A*A

Percent

80
70
60
50
40
30
20

BD
A

10
5

Effect Type
Not Significant
Significant

1
-10

10

20

30

Standardized Effect
Fig. 4. Normal probability plot of effects of factors and their interactions on wear of AlSiCGr hybrid composites.

Table 9
Percentage contribution of signicant factors affecting wear of AlSiCGr hybrid composites.
Factor

BC

BD

CD

AA

BB

DD

Error and others

2.84

12.76

6.40

71.92

0.71

0.61

1.01

0.23

0.54

1.34

1.64

nient for comparison of two and more number of responses. The %

reinforcement is considered as the common factor and the overlaid
contour plots are drawn in combination with sliding distance, load
and sliding speed.
Fig. 7 is the overlaid contour plot of wear of AlSiC composites
and AlSiCGr hybrid composites in terms of % reinforcement and
sliding distance. It is evident from the plot that as the % reinforcement increases, the wear of AlSiC composites continuously decreases for a particular value of sliding distance. The wear
decreases from 0.0323 to 0.252 g for an increase in % reinforcement

from 3% to 7.4% for a sliding distance of 1998 m. This trend prevails

up to % reinforcement of 10% at which the wear is 0.0223 g. This
can be attributed to the formation of a mechanically mixed layer
(MML). Reduction of wear is the consequence of the existence of
MML, which prevents the wear of matrix alloy. This behaviour is
in agreement with the reported observations on LM1310SiC composites [3].
The wear of AlSiCGr hybrid composites decreases with increase in % reinforcement up to a % reinforcement of 7.4%, but it
exhibits an increasing trend beyond % reinforcement of 7.4% for a

1809

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

cation of Gr particles, which get released during sliding and forming a tribo layer at the contact surfaces. The tendency for the wear
to increase beyond % reinforcement of 7.4% may be attributed
todecrease in fracture toughness. Wear studies carried out on
A35610SiC composites with Gr reinforcement up to 8% has exhibited a reverse trend, wherein the wear increases up to 5% of Gr and
then starts decreases. Decrease of fracture toughness and increased
effect of solid lubrication of Gr particles with increase in % reinforcement of Gr particles are the two identied competitive factors
responsible for the observed trend of A35610SiC composites [6].
The difference in the trends may be attributed to the way the reinforcement of SiC and Gr is incorporated in the two composites.
That is, the % reinforcement of SiC remains unchanged for A356
10SiC composites but it is equal to that of Gr for AlSiCGr hybrid
composites used in the present investigation.
It can be noticed from the plot that the wear increases with sliding distance for any amount of % reinforcement for both AlSiC
composites and AlSiCGr hybrid composites. This can be due to
unstable MML in AlSiC composites. It has been noticed that, at
longer sliding distances, there is a tendency of an increase in subsurface microcracking and severe fracturing of the SiC particles.
The fractured SiC particles cause further scratching on the surface
of composites and make the MML unstable [3]. The increase in
wear of AlSiCGr hybrid composites may be due to the weakened
tribo layer. Similar results have been reported on wear rates of
A356 Al10SiC4Gr hybrid composites, which showed a drastic increase with the sliding distance and shortly after the removal of
tribo layers the composite seized against the steel counterface [7].
The amount of wear is considerably less for AlSiCGr hybrid
composites than for AlSiC composites as can be observed from
the plot at.% reinforcement of 2.0% and for a sliding distance of
550 m. Similar observation can be made at.% reinforcement of
6.0% and for a sliding distance of 799 m.
The overlaid contour plot of % reinforcement in combination
with sliding speed for wear of AlSiC composites and AlSiCGr
hybrid composites is shown in Fig. 8. It can be observed that the
wear decreases for both the composites as the % reinforcement increases for any value of sliding speed. The values of wear and the
trend at a sliding speed of 1.99 m/s are identical to those observed
for a sliding distance of 1998 m in Fig. 7. It is evident from the plot
that the wear decreases with increase in sliding speed for any
amount of reinforcement in both AlSiCGr hybrid composites

Table 10
Response surface regression: wear (AlSiC), W versus AD. The analysis was done
using coded units. Estimated regression coefcients for W(AlSiC).
Term

Coefcients

SE coefcients

Constant
A
B
C
D
AA
BB
CC
DD
AB
AC
AD
BC
BD
CD

0.010067
0.001342
0.002233
0.002042
0.004700
0.000419
0.000781
0.000369
0.000356
0.000013
0.000538
0.000863
0.000687
0.000513
0.000762

0.001127
0.000398
0.000398
0.000398
0.000398
0.000423
0.000423
0.000423
0.000423
0.000488
0.000488
0.000488
0.000488
0.000488
0.000488

8.932
3.367
5.605
5.124
11.795
0.991
1.848
0.872
0.843
0.026
1.101
1.767
1.409
1.050
1.562

0.000
0.006
0.000
0.000
0.000
0.341
0.089
0.400
0.416
0.980
0.292
0.103
0.184
0.314
0.144

S = 0.001952, R-Sq = 94.9%, R-Sq(adj) = 88.9%.

Table 11
Response surface regression of wear (AlSiCGr), W versus AD. The analysis was
done using coded units. Estimated regression coefcients for wear, W.
Term

Coefcients

SE coefcients

Constant
A
B
C
D
AA
BB
CC
DD
AB
AC
AD
BC
BD
CD

0.008667
0.000846
0.001796
0.001271
0.004263
0.000416
0.000478
0.000147
0.000616
0.000031
0.000019
0.000006
0.000519
0.000481
0.000619

0.000443
0.000157
0.000157
0.000157
0.000157
0.000166
0.000166
0.000166
0.000166
0.000192
0.000192
0.000192
0.000192
0.000192
0.000192

19.567
5.401
11.468
8.115
27.220
2.502
2.879
0.884
3.706
0.163
0.098
0.033
2.705
2.509
3.226

0.000
0.000
0.000
0.000
0.000
0.028
0.014
0.394
0.003
0.873
0.924
0.975
0.019
0.027
0.007

S = 0.0007672, R-Sq = 98.8%, R-Sq (adj) = 97.5%.

sliding distance of 1998 m. This is evidenced from the plot as the

values of wear are 0.0234, 0.0221 and 0.0225 g, respectively, at.%
reinforcements of 3%, 7.4% and 10%. This is due to the solid lubri-

Residuals Versus the Fitted Values

(response is W(Al-SiC))
0.004
0.003

Residual

0.002
0.001
0.000
-0.001
-0.002
-0.003
0.000

0.005

0.010

0.015

0.020

Fitted Value
Fig. 5. Plot of residuals versus tted values of wear of AlSiC composites.

0.025

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S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

Residuals Versus the Fitted Values

(response is W(Al-SiC-Gr))
0.0010

Residual

0.0005

0.0000

-0.0005

-0.0010

-0.0015
0.000

0.005

0.010

0.015

0.020

Fitted Value
Fig. 6. Plot of residuals versus tted values of wear of AlSiCGr hybrid composite.

Overlaid Contour Plot of W(Al-SiC), g, W(Al-SiC-Gr), g

2000

1750

Sliding distance, m

W(Al-SiC), g
0.012
0.036

% Reinforcement = 7.40800
Sliding distance, m = 1998.14
W(Al-SiC), g = 0.0252547
W(Al-SiC-Gr), g = 0.0221286

W(Al-SiC-Gr), g
0.005
0.025

% Reinforcement = 3.00257
Sliding distance, m = 1998.14
W(Al-SiC), g = 0.0323807
W(Al-SiC-Gr), g = 0.0234328

1500

Hold Values
Sliding speed, m/s
Load, N

1250

% Reinforcement = 9.97388
Sliding distance, m = 1998.36
W(Al-SiC), g = 0.0223054
W(Al-SiC-Gr), g = 0.0225624

% Reinforcement = 2.00954
Sliding distance, m = 550.746
W(Al-SiC), g = 0.0113170
W(Al-SiC-Gr), g = 0.00686230

1000

2
75

% Reinforcement = 8.90015
Sliding distance, m = 1997.31
W(Al-SiC), g = 0.0234198
W(Al-SiC-Gr), g = 0.0222576

750

% Reinforcement = 6.01776
Sliding distance, m = 799.201
W(Al-SiC), g = 0.0116282
W(Al-SiC-Gr), g = 0.00682036

500
0

10

% Reinforcement
Fig. 7. Overlaid contour plot of effect of % reinforcement and sliding distance on wear of AlSiC composites and AlSiCGr hybrid composites.

and AlSiC composites. The decrease of wear with increase of sliding speed may be because of the increased effectiveness of the
MML in AlSiC composites and the tribo layer in AlSiCGr hybrid
composites. That is, high sliding speed may results in quick formation of tribo layer (or MML) and there by the wear gets reduced.
The amount of wear is less for AlSiCGr hybrid composites than
for AlSiC composites as can be observed from the plot at.% reinforcement of 2.0% and for a sliding speed of 0.5 m/s. Similar observation can be made at.% reinforcement of 6.0% and for a sliding
speed of 1.1 m/s.
Fig. 9 depicts the overlaid contour plot of % reinforcement in
combination with load for wear of AlSiC composites and Al
SiCGr hybrid composites. It is clear from the plot that the wear
decreases with increase in % reinforcement. At a load of 74.9 N,
the values of wear and the trend are similar to those noticed for
a sliding distance of 1998 m in Fig. 7 and also at a sliding speed

of 1.99 m/s in Fig. 8. It is observed from the plot that the wear increases with load for any amount of reinforcement. The increase in
wear of AlSiC composites at high loads may be due to increased
pressure on the MML resulting in transverse and longitudinal
cracks of MML as observed in LM1310SiC composite [3]. Similarly,
the increase of wear of AlSiCGr hybrid composites with increase
of load may be due to the reduced effect of the tribo layer. Increase
in load weakens the existing tribo layer resulting in transition from
mild to severe wear as noticed in case of A356 Al10SiC4Gr hybrid composites [7]. The amount of wear is less for AlSiCGr hybrid composite than for AlSiC composite as can be observed
from the plot at.% reinforcement of 2.0% and for a load of 19 N. Similar observation can be made at.% reinforcement of 6.0% and for a
load of 45 N.
The overlaid contour plots of Figs. 79 shows the effect of %
reinforcement on wear of AlSiC composites and AlSiCGr hybrid

1811

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

Overlaid Contour Plot of W(Al-SiC), g, W(Al-SiC-Gr), g

2.00

1.75

Sliding speed, m/s

W(Al-SiC), g
0.025
0.045

% Reinforcement = 7.41477
Sliding speed, m/s = 1.99731
W(Al-SiC), g = 0.0252643
W(Al-SiC-Gr), g = 0.0221597

W(Al-SiC-Gr), g
0.024
0.032

% Reinforcement = 3.00584
Sliding speed, m/s = 1.99731
W(Al-SiC), g = 0.0324003
W(Al-SiC-Gr), g = 0.0234623

1.50

Hold Values
Load, N
75
Sliding distance, m 2000

1.25

% Reinforcement = 9.98031
Sliding speed, m/s = 1.99731
W(Al-SiC), g = 0.0223108
W(Al-SiC-Gr), g = 0.0225916

1.00

% Reinforcement = 8.89708
Sliding speed, m/s = 1.99731
W(Al-SiC), g = 0.0234502
W(Al-SiC-Gr), g = 0.0223025

% Reinforcement = 2.01763
Sliding speed, m/s = 0.501522
W(Al-SiC), g = 0.0407336
W(Al-SiC-Gr), g = 0.0302416

0.75

% Reinforcement = 6.00847
Sliding speed, m/s = 1.14301
W(Al-SiC), g = 0.0281809
W(Al-SiC-Gr), g = 0.0240528

0.50
0

10

% Reinforcement
Fig. 8. Overlaid contour plot of effect of % reinforcement and sliding speed on wear of AlSiC composites and AlSiCGr hybrid composites.

Overlaid Contour Plot of W(Al-SiC), g, W(Al-SiC-Gr), g

70

60

Load, N

W(Al-SiC), g
0.01
0.035

% Reinforcement = 7.40827
Load, N = 74.9344
W(Al-SiC), g = 0.0252555
W(Al-SiC-Gr), g = 0.0221483

W(Al-SiC-Gr), g
0.009
0.025

% Reinforcement = 3.01080
Load, N = 74.9344
W(Al-SiC), g = 0.0323691
W(Al-SiC-Gr), g = 0.0234475

Hold Values
Sliding speed, m/s
2
Sliding distance, m 2000

50

% Reinforcement = 9.98738
Load, N = 74.9344
W(Al-SiC), g = 0.0222890
W(Al-SiC-Gr), g = 0.0225829

40

% Reinforcement = 8.89265
Load, N = 74.9344
W(Al-SiC), g = 0.0234393
W(Al-SiC-Gr), g = 0.0222904

% Reinforcement = 2.00884
Load, N = 19.0513
W(Al-SiC), g = 0.0131810
W(Al-SiC-Gr), g = 0.0109549

30

% Reinforcement = 6.01666
Load, N = 45.1004
W(Al-SiC), g = 0.0163639
W(Al-SiC-Gr), g = 0.0158289

20
0

10

% Reinforcement
Fig. 9. Overlaid contour plot of effect of % reinforcement and load on wear of AlSiC composites and AlSiCGr hybrid composites.

composites for all the values of sliding distance, sliding speed and
load within the range considered in the present investigation. It is
evident from these plots that, the amount of wear is the least for
AlSiCGr hybrid composites at around % reinforcement of 7.5%
beyond which it has a tendency to increase up to % reinforcement
of 10%. But this trend is not observed in case of AlSiC composites.
It is observed from the plots that the amount of wear is less up to %
reinforcement of 7.5% for AlSiCGr hybrid composites than for Al
SiC composites for any values of sliding distance, sliding speed and
load. Thus, it can be concluded that the optimal % reinforcement is
around 7.5% considering all the factors affecting wear of AlSiCGr
hybrid composites. There is no such % reinforcement for AlSiC
composites. The % contribution of % reinforcement is 4.85% in
AlSiC composites and 2.84% in AlSiCGr hybrid composites as
indicated, respectively, in Tables 8 and 9. But still AlSiCGr

hybrid composites exhibit better wear resistance than AlSiC

composites.

5. Conclusions
Experiments are conducted on AlSiC composites with reinforcement up to 10% and AlSiCGr hybrid composites with combined reinforcement up to 10% using pin-on-disc equipment.
Following are the conclusions of the investigation.
 % reinforcement, sliding speed, load and sliding distance affect
the wear. Interactions exist among sliding speed, load and sliding distance in AlSiCGr hybrid composites and such interactions do not exist in AlSiC composites.

1812

S. Suresha, B.K. Sridhara / Materials and Design 31 (2010) 18041812

 Increase of speed reduces wear by supporting mechanically

mixed tribo layer and increase of load increases wear by reducing the role of tribo layer. Wear increases with sliding distance
and it is the predominant factor affecting wear of both the
composites.
 Mathematical models using response surface regression analysis
is formulated and overlaid contour plots representing the model
have been drawn with % reinforcement being the common factor
in combination with sliding distance, sliding speed and load.
 Analysis of overlaid contour plots envisages that, increase in %
reinforcement reduces wear up to around 7.5% of % reinforcement and beyond this the wear has a tendency to increase for
AlSiCGr hybrid composites. Thus, the optimal % reinforcement
can be around 7.5% for any value of sliding distance, sliding
speed and load within the range considered in the investigation.
 Overlaid contour plots depict that wear continuously decreases
with increase in % reinforcement for AlSiC composites and thus
not evidencing the possibility of any optimal % reinforcement.
 In tribological applications demanding similar strength requirement, AlSiCGr hybrid composites are best suited than AlSiC
composites on account of lesser amount of wear.
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