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Research Papers

Study on Tribological Properties of Al–Al2O3 Composites Prepared Through FDMAIC Route Using Reinforced Sacrificial Patterns

[+] Author and Article Information
Sunpreet Singh

Dept. of Production Engineering, GNDEC,
Punjab Technical University,
Kapurthala 144601, India
e-mail: snprt.singh@gmail.com

Rupinder Singh

Professor
Dept. of Production Engineering, GNDEC,
Ludhiana 141006, India
e-mail: rupindersingh78@yahoo.com

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received January 10, 2015; final manuscript received May 14, 2015; published online September 9, 2015. Editor: Y. Lawrence Yao.

J. Manuf. Sci. Eng 138(2), 021009 (Sep 09, 2015) (10 pages) Paper No: MANU-15-1023; doi: 10.1115/1.4030772 History: Received January 10, 2015

In the present work, an attempt has been made to study the tribological properties of Al–Al2O3 composites (under dry sliding conditions) prepared via fused deposition modeling assisted investment casting (FDMAIC) route. Initially, two proportions/mixtures—nylon60%–Al30%–Al2O310% and nylon60%–Al 28%–Al2O312%—were fabricated in the form of fused deposition modeling (FDM) filament on a single screw extruder of L/D 20. Finally, the alternative filaments were used as feedstock filaments of existing FDM system for the fabrication of reinforced investment casting (IC) sacrificial patterns. The effect of process parameters (namely, filament proportion (FP), volume of reinforced FDM pattern, density of FDM pattern (DP), barrel finishing (BF) time, barrel finishing media weight (BFW), and number of IC slurry layers (NSL)) on tribological properties of Al–Al2O3 composites has been studied and optimized using Taguchi L18 OA. Tribotests were performed on pin-on-disk type tribotester at a sliding speed: 239 rpm, sliding diameter-80 mm, load-19.61 N, and time-10 min. Wear was measured both in terms of length and weight loss. Finally, the composites developed were characterized by using optical microscope, scanning electron microscope (SEM), energy dispersive spectroscopy (EDS), and X-ray diffractogram (XRD).

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Figures

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Fig. 1

Extruded reinforced FDM filament

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Fig. 2

(a) Fabrication of FDM based IC sacrificial pattern and (b) fabricated IC sacrificial patterns

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Fig. 3

(a) IC trees, (b) ceramic mould, and (c) casted composites

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Fig. 4

(a) Pin-on-disk apparatus and (b) real contact between pin and wear disk

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Fig. 5

Specimen mounting for microstructure analysis

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Fig. 6

Microstructures of Al–Al2O3 composite

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Fig. 7

(a) SEM image of Exp. No. 3 and (b) Exp. No.12 (at 200×)

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Fig. 8

(a) EDS plot of Exp. No. 3 and (b) Exp. No. 12

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Fig. 9

(a) XRD plot of Exp. No. 3 and (b) Exp. No. 12

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Fig. 10

(a)S/N responses to wear data and (b) mean data response to wear at “smaller the better” condition

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