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<p>This study investigates the fretting wear behavior of friction stir welded Aluminum alloy composites reinforced with different ratios of Silicon Carbide (SiC) and Molybdenum disulfide (MoS<sub>2</sub>). The study examines the impact of reinforcement on wear resistance, frictional properties, and microstructural features under loads of 20, 40, and 60 N using linear reciprocating tribometer. Experimental results indicate that hybrid composites exhibit superior wear resistance compared to the base AA2024 alloy. The optimal composition (AA2024 + 3% MoS<sub>2</sub> + 6% SiC) S3 sample exhibits remarkable improvements with the lowest wear rate of 3.92 × 10<sup>–3</sup>&#xa0;mm<sup>3</sup>/ N-m at 60 N, outperforming the (AA2024) S1 sample by 39%. The frictional force reduced from 11.048 N (S1) to 6.27 N (S3) at 60 N, the coefficient of friction for S3 is significantly decreased by 51.8%, 46.7%, and 35.2% at 20, 40, and 60 N load respectively. Due to particle agglomeration observed by scanning electron microscopy, a higher reinforcement content (AA2024 + 4% MoS<sub>2</sub> + 8% SiC) S4 sample exhibits slightly lesser performance, even with more reinforcement due to localized heating leading into partial softening of the matrix and stress concentration due to particle agglomeration. Microstructural analysis reveals that the uniform distribution of reinforcements in S3 produces a synergistic effect whereby MoS<sub>2</sub> forms a protective lubricating transfer film and SiC particles provide load-bearing hardness, thereby transferring wear mechanism from severe adhesive-abrasive damage to mild abrasive wear. Reinfrocement content upto 9%, the friction stir welding parameters (600&#xa0;rpm, 40&#xa0;mm/min) showed better performace; after that, particle clustering reduces the tribological benefits in 12% reinforcement with these parameters.</p>

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Effect of Hybrid SiC–MoS2 Reinforcement on Fretting Wear in Friction Stir Welding Aluminum 2024 Composites

  • 期刊论文

  • 发表日期：

    2026年1月2日

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  • Rathan Kumar Krishna Murthy,
  • Harohalli Manchaiah Nanjunda Swamy,
  • Sadashiva Mariyaiah,
  • G. K. Manjunath,
  • Hassan Rajamudigowda Anand,
  • Sharath Peramenahalli Chikkegowda

摘要

This study investigates the fretting wear behavior of friction stir welded Aluminum alloy composites reinforced with different ratios of Silicon Carbide (SiC) and Molybdenum disulfide (MoS2). The study examines the impact of reinforcement on wear resistance, frictional properties, and microstructural features under loads of 20, 40, and 60 N using linear reciprocating tribometer. Experimental results indicate that hybrid composites exhibit superior wear resistance compared to the base AA2024 alloy. The optimal composition (AA2024 + 3% MoS2 + 6% SiC) S3 sample exhibits remarkable improvements with the lowest wear rate of 3.92 × 10–3 mm3/ N-m at 60 N, outperforming the (AA2024) S1 sample by 39%. The frictional force reduced from 11.048 N (S1) to 6.27 N (S3) at 60 N, the coefficient of friction for S3 is significantly decreased by 51.8%, 46.7%, and 35.2% at 20, 40, and 60 N load respectively. Due to particle agglomeration observed by scanning electron microscopy, a higher reinforcement content (AA2024 + 4% MoS2 + 8% SiC) S4 sample exhibits slightly lesser performance, even with more reinforcement due to localized heating leading into partial softening of the matrix and stress concentration due to particle agglomeration. Microstructural analysis reveals that the uniform distribution of reinforcements in S3 produces a synergistic effect whereby MoS2 forms a protective lubricating transfer film and SiC particles provide load-bearing hardness, thereby transferring wear mechanism from severe adhesive-abrasive damage to mild abrasive wear. Reinfrocement content upto 9%, the friction stir welding parameters (600 rpm, 40 mm/min) showed better performace; after that, particle clustering reduces the tribological benefits in 12% reinforcement with these parameters.