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<p>Aluminum matrix composites are progressively utilized in automotive, aerospace, and structural applications that necessitate lightweight materials with superior wear resistance and consistent frictional properties under rigorous operating conditions. Enhancing the tribological performance of aluminum alloys by appropriate reinforcement techniques and effective multi-objective optimization is a significant task. This work examined and refined tribological attribute of stir-cast AA8011 aluminum matrix composites augmented with bimodal micro-sized silicon dioxide (SiO₂) particles. A constant reinforcement content of 5 wt% SiO₂, consisting of 20 and 60&#xa0;μm particles in 1:1 ratio, was chosen to improve particle packing, load transfer, and wear resistance. Dry sliding wear tests was performed with a pin-on-disc tribometer, manipulating sliding velocity, wear temperature, and applied stress according to a Taguchi L9 experimental design. Friction coefficient and Wear rate was seen as conflicting performance metrics. The objective weighing of tribological criteria was accomplished by the (MEREC) Method based on the Removal Effects of Criteria, while the (COPRAS) Complex Proportional Assessment method were utilized to evaluate experimental alternatives and ascertain ideal operating circumstances. The optimized parameter combination achieved a maximum reduction of 44.48% in wear rate and 79.77% in friction coefficient relative to unreinforced AA8011. Analyses of microstructure and wear mechanisms through scanning electron microscopy validated the shift from severe abrasive and delaminative wear to mild abrasive wear and stable tribofilm formation under optimized conditions. The suggested experimental-computational framework offers a rigorous and impartial approach for the design of wear-resistant aluminum matrix composites for advanced engineering applications.</p>

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Tribological performance enhancement of stir-cast AA8011 aluminum composites using bimodal SiO₂ reinforcement and MEREC–COPRAS optimization

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Viranshu Kumar,
  • Karrar Hussain,
  • Ganesh Babu L.,
  • Arunkumar S.,
  • Sam Charles Devaprasad J.,
  • Saravanan M.

摘要

Aluminum matrix composites are progressively utilized in automotive, aerospace, and structural applications that necessitate lightweight materials with superior wear resistance and consistent frictional properties under rigorous operating conditions. Enhancing the tribological performance of aluminum alloys by appropriate reinforcement techniques and effective multi-objective optimization is a significant task. This work examined and refined tribological attribute of stir-cast AA8011 aluminum matrix composites augmented with bimodal micro-sized silicon dioxide (SiO₂) particles. A constant reinforcement content of 5 wt% SiO₂, consisting of 20 and 60 μm particles in 1:1 ratio, was chosen to improve particle packing, load transfer, and wear resistance. Dry sliding wear tests was performed with a pin-on-disc tribometer, manipulating sliding velocity, wear temperature, and applied stress according to a Taguchi L9 experimental design. Friction coefficient and Wear rate was seen as conflicting performance metrics. The objective weighing of tribological criteria was accomplished by the (MEREC) Method based on the Removal Effects of Criteria, while the (COPRAS) Complex Proportional Assessment method were utilized to evaluate experimental alternatives and ascertain ideal operating circumstances. The optimized parameter combination achieved a maximum reduction of 44.48% in wear rate and 79.77% in friction coefficient relative to unreinforced AA8011. Analyses of microstructure and wear mechanisms through scanning electron microscopy validated the shift from severe abrasive and delaminative wear to mild abrasive wear and stable tribofilm formation under optimized conditions. The suggested experimental-computational framework offers a rigorous and impartial approach for the design of wear-resistant aluminum matrix composites for advanced engineering applications.