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<p>Tungsten–copper (W–Cu) composites are vital for high-temperature electrical contacts, where wear resistance dictates service life. This study employs Taguchi’s L<sub>9</sub> orthogonal array to minimize dry-sliding wear rate by optimizing three key parameters: reinforcement percentage (20–40%), temperature (160–200&#xa0;°C), and load (80–100 N). Wear tests were conducted on a pin-on-disc tribometer, and results were analyzed using signal-to-noise (S/N) ratios (smaller-the-better) and ANOVA. The optimum condition 30% reinforcement, 200&#xa0;°C, 80N yielded the lowest wear rate of&#xa0;3.498 × 10 − 73.498 × 10<sup>−7</sup>&#xa0;mm<sup>3</sup>/Nm. ANOVA revealed temperature as the most influential factor (90.6% contribution), followed by reinforcement (7.5%) and load (1.8%). Validation experiments confirmed prediction accuracy with 4.6% error. The study demonstrates Taguchi’s effectiveness in identifying a robust parameter set for enhanced wear performance in W–Cu composites, offering practical guidance for industrial applications.</p>

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Optimization of Wear Rate in Tungsten–Copper Metal Matrix Composites: A Robust Design Approach

  • 期刊论文

  • 发表日期：

    2026年6月3日

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  • Chandrashekhar R. Ingle,
  • Aniruddha M. Nikalje,
  • Sameer Sayyad

摘要

Tungsten–copper (W–Cu) composites are vital for high-temperature electrical contacts, where wear resistance dictates service life. This study employs Taguchi’s L9 orthogonal array to minimize dry-sliding wear rate by optimizing three key parameters: reinforcement percentage (20–40%), temperature (160–200 °C), and load (80–100 N). Wear tests were conducted on a pin-on-disc tribometer, and results were analyzed using signal-to-noise (S/N) ratios (smaller-the-better) and ANOVA. The optimum condition 30% reinforcement, 200 °C, 80N yielded the lowest wear rate of 3.498 × 10 − 73.498 × 10−7 mm3/Nm. ANOVA revealed temperature as the most influential factor (90.6% contribution), followed by reinforcement (7.5%) and load (1.8%). Validation experiments confirmed prediction accuracy with 4.6% error. The study demonstrates Taguchi’s effectiveness in identifying a robust parameter set for enhanced wear performance in W–Cu composites, offering practical guidance for industrial applications.