Investigating the Impact of Dual-Range Iron Slag Particles-Reinforced Aluminum Composite for Dry Sliding Applications

In the present study, aluminum matrix composites have synthesized through the liquid metallurgy method. The impact of iron slag reinforcement with dual-range particle size has been thoroughly examined in these composites for wear applications. The 15 wt.% iron slag-reinforced aluminum metal matrix composites, with a fine-to-coarse ratio of 4:1, demonstrated prominent outcomes. Significantly, the composite demonstrated a notable improvement in wear resistance and coefficient of friction, with a remarkable reduction of 62% in wear rate and 42% in coefficient of friction compared to the LM30 (Al alloy). The steady-state wear rate of the aluminum metal matrix composites was merely 9% lower when compared to cast iron utilized in brake rotor applications. In the dual-sized particles of Fe-slag, coarse particles enhance wear resistance by withstanding higher loads and preventing localized high-stress areas, while fine particles boost dislocation density and increase hardness. The combination promotes balanced load distribution and work hardening during wear. The significant reduction in wear rate and coefficient of friction in 15 wt.% iron slag-reinforced aluminum metal matrix composites compared to LM30 and cast iron is primarily due to enhanced abrasive wear resistance, reduced adhesive wear, and the formation of a protective tribolayer. Micro-cracks were identified alongside plastic deformation under a higher pressure of 1.4 MPa. This led to material deformation in the form of a delaminated layer.