Study the formation of mechanically mixed layer and subsurface behavior of worn-out surfaces of aged hybrid metal matrix composites

Purpose This paper aims to investigate the wear behaviors of aged metal matrix composites and of the as-cast Al-Si alloy by using a pin-on-disk wear testing machine at room temperature. Design/methodology/approach Hypoeutectic (Al-7Si) alloy reinforced with low volume fractions of SiC particles (SiCp) and graphite (Gr) particles were prepared by the stir-casting process. It was found that the addition of 9 Wt.% of SiCp and 3 Wt.% of Gr particles conferred a beneficial effect in reducing the wear rate of the composites. Findings The worn-out surfaces of the specimens were examined using scanning electron microscopy (SEM); the extensive micro cracking occurs on the surface of the Al-7Si alloy tested at lower loads. The growth of these microcracks finally led to the delamination of the base alloy surface. The reinforcements (SiCp and Gr) particles tended to reduce the extent of plastic deformation in the surface layer, thereby reducing extensively the occurrence of micro cracking in the composites. Originality/value From the results, it is revealed that the quantity of wear rate was less for aged specimens compared to the as-cast specimens. The worn-out surfaces were studied using electron dispersive spectroscopy, and wear debris was analyzed using SEM.