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<p>The strain-induced melt activation (SIMA) method was applied to study the physical, microstructural, and wear properties of a hypereutectic Al-Si alloy with 16% and 20% silicon. The SIMA process involved multidirectional forging at 300 ± 10°C, followed by semi-solid treatment at 580 ± 10°C for 0–30 minutes. Techniques like x-ray diffraction, optical microscopy, scanning electron microscopy, and atomic force microscopy analyzed phase composition, microstructural evolution, and wear behavior in as-cast and SIMA-processed samples. Hardness, density, and porosity were measured. The S2 sample showed the highest hardness (73–86 VHN) and lowest density (2.68–2.49 g/cm³) compared to as-cast and multidirectional forged samples, due to refined phases and low-density silicon particles. Wear tests at room temperature, with a 1500 m sliding distance, velocities of 1–3 m/s, and loads of 15–45 N, showed that SIMA-processed samples, with refined grains and spherical morphology, had 50% and 65% lower wear rates for 16% and 20% Si alloys, respectively, at optimal conditions (580 ± 10°C, 10 minutes). SEM revealed wear surfaces shifting from mild abrasion at low loads/speeds to severe grooving at higher conditions, with SIMA samples showing less damage due to globular microstructures. The friction coefficient ranged from 0.45 to 0.58. AFM indicated increased surface roughness with load and velocity, with SIMA-treated samples showing the least roughness. SIMA processing enhanced wear resistance and mechanical properties, making these alloys ideal for lightweight automotive and aerospace applications.</p>

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Microstructural, Physical Property, and Wear Behavior Correlationship of SIMA-Processed Al-16% Si and Al-20% Si Alloy

  • 期刊论文

  • 发表日期：

    2025年11月19日

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  • Choudhary Ishwari Narain,
  • Sinha Nitesh Kumar,
  • Mahali Manik,
  • J. K. Singh

摘要

The strain-induced melt activation (SIMA) method was applied to study the physical, microstructural, and wear properties of a hypereutectic Al-Si alloy with 16% and 20% silicon. The SIMA process involved multidirectional forging at 300 ± 10°C, followed by semi-solid treatment at 580 ± 10°C for 0–30 minutes. Techniques like x-ray diffraction, optical microscopy, scanning electron microscopy, and atomic force microscopy analyzed phase composition, microstructural evolution, and wear behavior in as-cast and SIMA-processed samples. Hardness, density, and porosity were measured. The S2 sample showed the highest hardness (73–86 VHN) and lowest density (2.68–2.49 g/cm³) compared to as-cast and multidirectional forged samples, due to refined phases and low-density silicon particles. Wear tests at room temperature, with a 1500 m sliding distance, velocities of 1–3 m/s, and loads of 15–45 N, showed that SIMA-processed samples, with refined grains and spherical morphology, had 50% and 65% lower wear rates for 16% and 20% Si alloys, respectively, at optimal conditions (580 ± 10°C, 10 minutes). SEM revealed wear surfaces shifting from mild abrasion at low loads/speeds to severe grooving at higher conditions, with SIMA samples showing less damage due to globular microstructures. The friction coefficient ranged from 0.45 to 0.58. AFM indicated increased surface roughness with load and velocity, with SIMA-treated samples showing the least roughness. SIMA processing enhanced wear resistance and mechanical properties, making these alloys ideal for lightweight automotive and aerospace applications.