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<p>In real engineering environments, automotive components such as cylinder liners, brake rotors, clutch plates, turbine blades, impellers and aerospace sliding assemblies are continuously exposed to entrapped hard particles originating from environmental dust, wear debris, oxide fragments and combustion by-products, resulting in three-body abrasive sliding wear. The development of aluminium matrix nanocomposites with improved wear resistance is often limited by challenges related to uniform dispersion, agglomeration and poor wettability of ceramic reinforcements. Additionally, controlling wear behaviour under abrasive conditions is one of the significant limitations for the effective application of aluminium matrix nanocomposites. Current research tries to address these challenges by evaluating the abrasive wear characteristics of LM6–Si<sub>3</sub>N<sub>4</sub> nanocomposites containing silicon nitride (Si<sub>3</sub>N<sub>4</sub>) nanoparticles at different weight percentages (wt%) (0.5– 2 wt%). Composites are synthesized through the ultrasonic-assisted stir casting route. Microstructural characterization using optical microscopy (OM), FESEM, EDS, elemental mapping and XRD techniques confirms the incorporation of reinforcement and the homogeneous dispersion. Mechanical characterization reveals 36% and 0.73% enhancements in microhardness and density simultaneously for LM6–2Si<sub>3</sub>N<sub>4</sub> nanocomposites compared to the LM6 matrix. Abrasive wear tests are conducted on a pin-on-disc tribotester using various abrasive grits (400– 800 SiC) and track diameters (30–50&#xa0;mm) and show substantial enhancement in wear resistance (85– 88%) and reduction in coefficient of friction (26– 77%) compared to the LM6 alloy. The enhanced wear behaviour is attributed to improve load-bearing capacity, uniform particle dispersion and restricted plastic deformation of the matrix. Worn surface analyses indicate severe abrasive–adhesive wear with deep ploughing and delamination for LM6 alloy while LM6–Si<sub>3</sub>N<sub>4</sub> nanocomposites possess mild abrasive–oxidative wear with shallow grooves as dominant wear mechanisms.</p>

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Abrasive Wear Characteristics of LM6–Si3N4 Nanocomposites Synthesized Using Ultrasonic-Assisted Stir Casting

  • 期刊论文

  • 发表日期：

    2026年5月23日

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  • Debayan Mandal,
  • Sudip Banerjee,
  • Ranjan Basak,
  • Joyjeet Ghose

摘要

In real engineering environments, automotive components such as cylinder liners, brake rotors, clutch plates, turbine blades, impellers and aerospace sliding assemblies are continuously exposed to entrapped hard particles originating from environmental dust, wear debris, oxide fragments and combustion by-products, resulting in three-body abrasive sliding wear. The development of aluminium matrix nanocomposites with improved wear resistance is often limited by challenges related to uniform dispersion, agglomeration and poor wettability of ceramic reinforcements. Additionally, controlling wear behaviour under abrasive conditions is one of the significant limitations for the effective application of aluminium matrix nanocomposites. Current research tries to address these challenges by evaluating the abrasive wear characteristics of LM6–Si3N4 nanocomposites containing silicon nitride (Si3N4) nanoparticles at different weight percentages (wt%) (0.5– 2 wt%). Composites are synthesized through the ultrasonic-assisted stir casting route. Microstructural characterization using optical microscopy (OM), FESEM, EDS, elemental mapping and XRD techniques confirms the incorporation of reinforcement and the homogeneous dispersion. Mechanical characterization reveals 36% and 0.73% enhancements in microhardness and density simultaneously for LM6–2Si3N4 nanocomposites compared to the LM6 matrix. Abrasive wear tests are conducted on a pin-on-disc tribotester using various abrasive grits (400– 800 SiC) and track diameters (30–50 mm) and show substantial enhancement in wear resistance (85– 88%) and reduction in coefficient of friction (26– 77%) compared to the LM6 alloy. The enhanced wear behaviour is attributed to improve load-bearing capacity, uniform particle dispersion and restricted plastic deformation of the matrix. Worn surface analyses indicate severe abrasive–adhesive wear with deep ploughing and delamination for LM6 alloy while LM6–Si3N4 nanocomposites possess mild abrasive–oxidative wear with shallow grooves as dominant wear mechanisms.