Development and Wear Behavior of Al/Al ₂ SiO ₅ /C Chilled Hybrid Metal Matrix Composites by Both Experimental and Finite Element Modeling

This paper describes research on aluminum-based metal matrix hybrid composites reinforced with kaolinite (Al₂SiO₅) and carbon (C) particulates cast using high rate heat transfer technique during solidification by employing metallic, non-metallic and cryogenic end chills. The effect of reinforcement and chilling on strength, hardness and wear behavior are discussed in this paper. It is discovered that cryogenic chilled MMCs with Al₂SiO₅-9 vol. %/C-3 vol. % dispersoid content proved to be the best in enhancing the mechanical and wear properties. A physically based finite element (FE) model for the abrasive wear of the hybrid composite developed is based on the mechanisms associated with sliding wear of ductile aluminum matrix of the composite containing hard Al₂SiO₅ and soft carbon (dry lubricant) reinforcement particles. Finally the results reveal that there is a good agreement that exists between the simulated (FE) values and those of the experimental values, proving the suitability of the boundary conditions.