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Table 4 Tribological variables and their levels optimised with the help of Taguchi’s methodology to get effective wear properties on the fabricated aluminium FG composite. Vicker’s microhardness of the respective region. XRD study was accomplished on the sample cut from the external periphery of the fabricated aluminium FG composite to confirm the existence of reinforcement in the aluminium matrix and to categorise some intermetallic phases formed during casting. D8 Advance, Davinci (BRUKER USA make) device was em- ployed to do XRD analysis in the range of 0.101 to 117.813° with a minimum step size of 0.029°.

Table 4 Tribological variables and their levels optimised with the help of Taguchi’s methodology to get effective wear properties on the fabricated aluminium FG composite. Vicker’s microhardness of the respective region. XRD study was accomplished on the sample cut from the external periphery of the fabricated aluminium FG composite to confirm the existence of reinforcement in the aluminium matrix and to categorise some intermetallic phases formed during casting. D8 Advance, Davinci (BRUKER USA make) device was em- ployed to do XRD analysis in the range of 0.101 to 117.813° with a minimum step size of 0.029°.

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Table 1 Properties of aluminium A356 alloy (Ref 22)
Table 1 Properties of aluminium A356 alloy (Ref 22)
Fig. 1 (a) SEM micrograph, (b) XRD of the as-received silicon nitride powder
Fig. 1 (a) SEM micrograph, (b) XRD of the as-received silicon nitride powder
Table 2 Chemical composition of aluminium A356 alloy (Ref 17)
Table 2 Chemical composition of aluminium A356 alloy (Ref 17)
Table 3 Properties of Si,N, (Ref 23, 24)
Table 3 Properties of Si,N, (Ref 23, 24)
Fig. 2 (a) Bottom pouring electric stir casting machine with inbuilt vertical centrifugal casting facility, (b) Vertical centrifugal casting facility, (c) Developed A356-10 wt.% Si3N, functionally graded composite
Fig. 2 (a) Bottom pouring electric stir casting machine with inbuilt vertical centrifugal casting facility, (b) Vertical centrifugal casting facility, (c) Developed A356-10 wt.% Si3N, functionally graded composite
Fig. 3. Pin-on-disc wear testing arrangement
Fig. 3. Pin-on-disc wear testing arrangement
Fig. 5 Schematic representation of the fabricated disc with spotted zones and locations of specimens cut for other characterisation
Fig. 5 Schematic representation of the fabricated disc with spotted zones and locations of specimens cut for other characterisation
Fig. 6 HRSEM image at (a) Wealthy ceramic zone (6-20 mm), (b) Transition zone (21-30 mm), (c) Wealthy matrix zone (31-40 mm
Fig. 6 HRSEM image at (a) Wealthy ceramic zone (6-20 mm), (b) Transition zone (21-30 mm), (c) Wealthy matrix zone (31-40 mm
Fig. 7 (a) Elemental mapping, (b) EDS graph of the fabricated FGMMC at the wealthy ceramic zone
Fig. 7 (a) Elemental mapping, (b) EDS graph of the fabricated FGMMC at the wealthy ceramic zone
Fig. 8 XRD peaks of A356 aluminium alloy FG composite at the wealthy ceramic zone Fig. 9 Hardness variation from the external towards the internal periphery of the FGMMC
Fig. 8 XRD peaks of A356 aluminium alloy FG composite at the wealthy ceramic zone Fig. 9 Hardness variation from the external towards the internal periphery of the FGMMC
Table 6 SNR response table for aluminium FG composite and Sajikumar (Ref 32) observed a comparable hardness mechanism for the Al-10 wt.% SiC ex situ functionally graded composite. However, no other reaction products were observed in the fabricated composite.
Table 6 SNR response table for aluminium FG composite and Sajikumar (Ref 32) observed a comparable hardness mechanism for the Al-10 wt.% SiC ex situ functionally graded composite. However, no other reaction products were observed in the fabricated composite.
Fig. 11 Mean wear rate of aluminium FG composite on their different zones Fig. 10 SNR main effect map for the sliding wear variables on the wear rate
Fig. 11 Mean wear rate of aluminium FG composite on their different zones Fig. 10 SNR main effect map for the sliding wear variables on the wear rate
Fig. 12 SEM image of the worn texture in the (a) wealthy matrix zone at 20 N, (b) wealthy matrix zone at 60 N, (c) wealthy matrix zone at 40 N, (d) 3D surface map of the wealthy matrix zone at 40 N, (e) 2D depth graph of the wealthy matrix zone at 40 N
Fig. 12 SEM image of the worn texture in the (a) wealthy matrix zone at 20 N, (b) wealthy matrix zone at 60 N, (c) wealthy matrix zone at 40 N, (d) 3D surface map of the wealthy matrix zone at 40 N, (e) 2D depth graph of the wealthy matrix zone at 40 N
Fig. 13 SEM image of the worn texture in the (a) transition zone at 20 N, (b) 3D surface map of transition zone at 20 N, (c) 2D depth graph of transition zone at 20 N
Fig. 13 SEM image of the worn texture in the (a) transition zone at 20 N, (b) 3D surface map of transition zone at 20 N, (c) 2D depth graph of transition zone at 20 N
Fig. 14 (a) EDS measured on the worn surface of the transition zone at 20 N, (b) Elemental mapping
Fig. 14 (a) EDS measured on the worn surface of the transition zone at 20 N, (b) Elemental mapping
Fig. 15 SEM image of the worn texture in the (a) transition zone at 40 N, (b) 3D surface map of the transition zone at 40 N, (c) 2D deptl graph of the transition zone at 40 N
Fig. 15 SEM image of the worn texture in the (a) transition zone at 40 N, (b) 3D surface map of the transition zone at 40 N, (c) 2D deptl graph of the transition zone at 40 N
Fig. 16 SEM image of the worn texture in the (a) transition zone at 60 N, (b) 3D surface map of the transition zone at 60 N, (c) 2D dept graph of the transition zone at 60 N
Fig. 16 SEM image of the worn texture in the (a) transition zone at 60 N, (b) 3D surface map of the transition zone at 60 N, (c) 2D dept graph of the transition zone at 60 N
Fig. 17 SEM image of the worn texture in the (a) wealthy ceramic zone at 20 N, (b) XRD, (c) 3D surface map of the wealthy ceramic zone a 20 N, (d) 2D depth graph of the wealthy ceramic zone at 20 N
Fig. 17 SEM image of the worn texture in the (a) wealthy ceramic zone at 20 N, (b) XRD, (c) 3D surface map of the wealthy ceramic zone a 20 N, (d) 2D depth graph of the wealthy ceramic zone at 20 N
Fig. 18 SEM image of the worn texture in the (a) wealthy ceramic zone at 40 N, (b) 3D surface map of the wealthy ceramic zone at 40 N, (c) 2D depth graph of the wealthy ceramic zone at 40 N
Fig. 18 SEM image of the worn texture in the (a) wealthy ceramic zone at 40 N, (b) 3D surface map of the wealthy ceramic zone at 40 N, (c) 2D depth graph of the wealthy ceramic zone at 40 N
Fig. 20 Mean coefficient of friction of aluminium FG composites on their different zones
Fig. 20 Mean coefficient of friction of aluminium FG composites on their different zones
Fig. 19 SEM image of the worn texture in the (a) wealthy ceramic zone at 60 N, (b) 3D surface map of the wealthy ceramic zone at 60 N, (c) 2D depth graph of the wealthy ceramic zone at 60 N
Fig. 19 SEM image of the worn texture in the (a) wealthy ceramic zone at 60 N, (b) 3D surface map of the wealthy ceramic zone at 60 N, (c) 2D depth graph of the wealthy ceramic zone at 60 N
Fig. 21 SEM image of the worn texture in the (a) matrix wealthy zone at 60 N, (b) transition zone at 40 N
Fig. 21 SEM image of the worn texture in the (a) matrix wealthy zone at 60 N, (b) transition zone at 40 N
Fig. 22 SEM image of the worn texture in the ceramic wealthy zone at (a) 20 N, (b) 60 N
Fig. 22 SEM image of the worn texture in the ceramic wealthy zone at (a) 20 N, (b) 60 N
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