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Effect of surface roughness on tribological properties of TiB

2
/Al
composites
S.F. Tian
a
, L.T. Jiang
a,b
, Q. Guo
a
, G.H. Wu
a,b,
a
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
b
State Key Laboratory of Advanced Welding Production Technology, Harbin Institute of Technology, Harbin 150001, China
a r t i c l e i n f o
Article history:
Received 25 November 2012
Accepted 25 February 2013
Available online 2 July 2013
Keywords:
Aluminium matrix composites
Tribological properties
Surface roughness
a b s t r a c t
55 vol.% TiB
2
/2024Al composites were fabricated by pressure inltration method. The effect of surface
roughness of GCr15 steel disc (Ra 0.606, 0.372, 0.023, 0.005 lm) on the tribological properties of compos-
ites was investigated. Results showed that with the change of surface roughness, there is an optimal value
(Ra 0.023 lm) under which the friction coefcient and wear rate is the lowest. The optimal surface rough-
ness is in the same order of mixture of TiO
2
and B
2
O
3
, observed on the surface of TiB
2
particles after pre-
heating process. During sliding, the lling of this oxidation layer into the asperity gap of GCr15 and
greatly reduces adhesion between aluminium and GCr15, furthermore, decreases the friction coefcient
and wear rate.
2013 Elsevier Ltd. All rights reserved.
1. Introduction
TiB
2
particles reinforced aluminiummatrix (TiB
2
/Al) composites
have been widely investigated due to their excellent properties. In
the past, effects of load [1,2], temperature [3] and reinforcement
volume fraction [1,2,4] on wear properties of TiB
2
/Al composites
have been reported. Kumar et al. [1] investigated Al7Si/10TiB
2
composites and concluded that adhesion and ploughing are pre-
dominant at lower loads and delamination is more predominant
at higher loads. Natarajan et al. [3] found that the wear mechanism
of Al 6063/TiB
2
composites at temperature less than 100 C is abra-
sive wear, above 200 C is oxidative wear. Mandal et al. [2] inves-
tigated effect of TiB
2
particles on sliding wear behaviour of Al4Cu
alloy, and found that wear resistance increases with increase in the
amount of TiB
2
. However, the surface roughness of frictional pair
(usually steel), which also plays an important role on tribological
properties, has not been well investigated yet. For convenience,
the surface roughness in the following paragraphs represents
surface roughness of frictional pair.
About the effect of surface roughness on tribological properties,
Amontons (1699) and Bowden proposed the most simple friction
model: the friction coefcient f = tanu, where u denoted the angle
between the asperity and the surface, from the formula it can be
concluded that the smoother the surface is, the lower the friction
coefcient is. However, these theories are too simple to explain
the complex tribological phenomena, and the do not fully consist
with the situation encountered in practice [5]. In 1975, Bayer and
Sirico investigated the inuence of surface roughness on wear.
They found that wear was more sensitive to surface roughness
variations for the ner surface (<V16) and wear was more sensitive
to orientation of the surface roughness for the coarser surface
(>V16) [6]. Wang and Rack [7] investigated the friction and wear
behaviour of 2124 AlSiC
w
/17-4 PH stainless steel systems under
dry sliding wear using a pin-on-disc apparatus, and they concluded
that reducing the surface roughness of the sliding surfaces signi-
cantly reduced initial wear rates in both surfaces, but had no effect
on the steady-state wear rate of either the pin or the disc. Ho-Chieh
et al. [8] investigated the effect of surface roughness on friction of
ceramics (Si
3
N
4
, SiC and Al
2
O
3
) sliding in water. They founded that
for Si
3
N
4
and SiC, smaller surface roughness provided smaller fric-
tion coefcient in run-in process. However, for Al
2
O
3
, specimen of
0.320 lm R
rms
shows larger friction coefcient than other Al
2
O
3
specimens of the same surface roughness. Sahin et al. [9] studied
effect of surface roughness on friction coefcients during upsetting
processes for different materials (steel, commercially pure alumin-
ium and annealed CuZn40Pb2 brass). Results showed that the fric-
tion coefcient depended on surface roughness where the rougher
surfaces gave lower friction coefcients for all materials.
From the reports above, it can be founded that the effect of sur-
face roughness on friction and wear is very complex, and it is not
sure that reducing surface roughness is better or not for the special
frictional system. At present, to nd optimal surface roughness, a
large number of tests must be carried out [710]. However, few
people considered the effect of microstructure on the optimal sur-
face roughness, and the relationship between the two in trilobogy.
In the present paper, 55 vol.% TiB
2
/2024Al composites were fab-
ricated by pressure inltration method and the effect of surface
0261-3069/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.matdes.2013.06.038

Corresponding author at: School of Materials Science and Engineering, Harbin


Institute of Technology, Harbin 150001, China. Tel./fax: +86 451 86412164.
E-mail address: wugh@hit.edu.cn (G.H. Wu).
Materials and Design 53 (2014) 129136
Contents lists available at SciVerse ScienceDirect
Materials and Design
j our nal homepage: www. el sevi er . com/ l ocat e/ mat des
roughness of GCr15 steel disc on tribological properties of compos-
ites was investigated to nd the optimal surface roughness.
2. Experimental details
55 vol.% TiB
2
/2024Al composites were prepared by pressure
inltration method. The average size of TiB
2
is 1.6 lm. The pre-
heating temperature of perform was between 600 and 650 C, cast-
ing temperature was between 750 and 770 C and casting pressure
was between 70 and 80 MPa. Phase analysis was characterized
using D/max-c b type X-ray diffraction instrument. FEI SIRION200
scanning electron microscope (SEM) and JEOL200CX transmission
electron microscope (TEM) were used to characterize the
microstructures.
The dry sliding wear tests were conducted on a pin-on-disc
wear testing machine (Model: CJS111A, Harbin, China) according
to the ASTM: G99-05 (2010). The composite was rst processed
into the dimensions of U3 13 mm of the rod. The end of sample
was then machined into hemispherical shape with the radius of
1.5 mm. Finally, samples were soluted at 495 C for 1 h, quenched
to room temperature in water, and then aged at 160 C for 10 h.
The counterface material used was GCr15 steel (China brand, cor-
responding to AISI52100 bearing steel), hardened to HRC60.
In order to investigate the effect of surface roughness of GCr15
steel disc on the tribological properties of composite, surface
roughness with values of Ra 0.005, 0.023, 0.372 and 0.606 lm were
selected. Specially, Ra 0.005 lm was obtained by manual lapping
and polishing, the other three were obtained by grinding machines
with different grinding wheel. Ra values were tested by atomic
force microscope (AFM) (NanoscopeIIIa, DI), according to the ISO:
4288 [11], 3D proles were shown in Fig. 1.
Friction and wear experiments, in which the load was xed to
50 g and the sliding speed, were from 1.0 to 2.0 m/s. The sliding
time for all the tests was 30 min. Before the test, the composite
was polished, and pin and disc were washed by acetone to remove
dirt. The worn surface of pin and disc was observed by scanning
electron microscope. The worn surfaces of pin were also analyzed
using PHI5700 ESCA system X-ray photoelectron spectroscopy
(XPS). Since one end of pin is hemisphere, after sliding, the shape
of wear volume is spherical segment. By SEM observation of worn
surface and corresponding mathematic equations, it is easily to cal-
culate wear volume [12]. And the wear rate can be calculated as:
Wear rate Wear volume=Load Distance Travelled 1
3. Results and discussion
3.1. Microstructure of TiB
2
after heat preservation
Fig. 2 gives TEM and HREM microstructure of the surface of a
TiB
2
particle, which was taken from the preform pre-heated at
640 C for 2 h. It can be seen that there was a layer with the thick-
ness of 2030 nm on the surface of TiB
2
particle. Local amplica-
tion of the layer is showed in Fig. 2b. Some nanoparticles were
formed in this layer, which resulted from the heat preservation
of perform. Fig. 2c is the HREM image of Fig. 2b. After calibration,
it was found that the layer on the surface was made up of TiO
2
and
B
2
O
3
nanoparticles with grain size of about 5 nm. The appearance
of TiO
2
and B
2
O
3
resulted from the reaction of TiB
2
with oxygen
during the heat preservation at 640 C of perform. This reaction fol-
lowed the following equation,
TiB
2
5=2O
2
! TiO
2
B
2
O
3
2
The reaction Gibbs free energy change at 640 C is 1552.14 KJ/
mol, based on JANAF Thermochemical Tables [13], which indicates
that this reaction can take place spontaneously.
Although no reaction would be occurred between pure TiB
2
phase and Al [14], the reaction between the formed nano-oxide
layer and molten Al would modify the TiB
2
/Al interface, and affect
friction behaviour of TiB
2
/2024Al composites.
Fig. 1. 3D proles of disc for different surface roughness.
130 S.F. Tian et al. / Materials and Design 53 (2014) 129136
3.2. Microstructure of TiB
2
/2024Al composite
Representative morphology of TiB
2
/2024Al composite was
shown in Fig. 3, TiB
2
particles were distributed uniformly without
any particle clustering and no apparent porosity or signicant cast-
ing defects were observed in the composites.
It can be seen from Fig. 4 that there were only two phases
including TiB
2
and a-Al in the composite, and almost no other
phase could be observed, especially TiAl compounds. This is quite
different fromthe composites that are fabricated by in situ reaction
[4,15], because molten aluminium is directly pressed into the pre-
pared TiB
2
preform by the method of pressure inltration method
under external forces instead of synthesizing TiB
2
by chemical
reaction, which is inevitably accompanied with by-product. By
observing the high-resolution electron microscope image (Fig. 2),
it could be found that a layer consisting of TiO
2
and B
2
O
3
could
be observed on the surface of TiB
2
particles after pre-heating, but
this could not be seen in XRD pattern. This was because the thick-
ness (2030 nm) of this surface layer was too small compared with
the size (1.6 lm) of TiB
2
particle. As a result, the content of TiO
2
and B
2
O
3
was rather low compared with the whole material, and
lower than the XRD detection limit (5%). Consequently, TiO
2
and
B
2
O
3
phases couldnt be observed in XRD diffraction pattern.
Representative microstructure of TiB
2
/Al interface was shown
in Fig. 5. Some interface of TiB
2
particles and matrix were straight
and clean. However, there were also some interface products, as
indicated by the white arrow in Fig. 5a, different from Mitras re-
port [14]. The reactant product in Fig. 5b is identied as TiO
2
,
and the reactant product in Fig. 5c and d is identied as B
2
O
3
.
The formation of TiO
2
and B
2
O
3
is from the oxidation of TiB
2
(Eq.
(2)), but we also nd Al
2
O
3
(Fig. 5c) and AlB
2
(Fig. 5d), and both
of two are near B
2
O
3
, therefore we can deduce the formation of
Al
2
O
3
and AlB
2
are related to B
2
O
3
.
At the casting temperature (700750 C), the Gibbs free energy
change of B
2
O
3
reacts with Al (Eq. (3)) is 486.96 KJ/mol, based on
JANAF Thermochemical Tables [13], which indicates that this reac-
tion can take place, as shown in Eq. (3). Hence, the generation of
Al
2
O
3
and AlB
2
is explained. Moreover, the interface with partial
reactant has higher bonding strength than TiB
2
Al interface with-
out any reactant, and maybe better wear resistance.
B
2
O
3
3Al Al
2
O
3
AlB
2
3
Fig. 2. TEM and HREM images of the surface of a TiB
2
particle, which was taken from the preform pre-heated at 640 C for 2 h. (a) TEM images of surface; (b) magnication of
(a) and (c) HREM image.
Fig. 3. SEM microstructure of 55 vol.% TiB
2
/2024Al composite.
Fig. 4. X-ray diffraction spectrum of 55 vol.% TiB
2
/2024Al composite.
S.F. Tian et al. / Materials and Design 53 (2014) 129136 131
3.3. Frictional behaviours of TiB
2
/2024Al composite
Figs. 6 and 7 show the curves of friction coefcients and wear
rate of TiB
2
/Al composite against GCr15 bearing steel as a function
of sliding speed and surface roughness under dry sliding condition
(P = 50 g). It can be seen that friction coefcient and wear rate
showed great difference with different surface roughness condi-
tions. Friction coefcient changed in the range of 0.350.5 and
0.250.55 for Ra 0.602 lm and Ra 0.372 lm, respectively. It
reached the lowest value of 0.080.15 if Ra declined to 0.023 lm.
However it increased to 0.40.6 with the surface roughness further
decreased to 0.005 lm. Wear rate showed the same trend with the
friction coefcient, possessing the lowest value with the Ra
0.0023 lm surface roughness.
Under the same speed, with the decrease of Ra, the wear rate
rst declined (Ra 0.606 lm?Ra 0.023 lm) and then ascended
(Ra 0.023 lm?Ra 0.005 lm), shown in Fig. 7. For friction coef-
cient, it was a little complex, since variation tendency at 1.5 and
2.0 m/s were not evident, but the overall trend was still rstly
down and then up, shown in Fig. 6. Friction coefcient and wear
rate for Ra 0.023 lm was the lowest. Tribological properties with
the variation of Ra are different from other peoples works [6
9,16]. For example, Sahin et al. [9] suggested the rougher surfaces
gave lower friction coefcients. Menezes et al. [16] indicated the
coefcient of friction does not vary much with surface roughness.
Fig. 5. TEM and HREM images of 55 vol.% TiB
2
/2024Al composite (a) TEM image of composite and (bd) HREM of image of interface reactant.
Fig. 6. Curves of friction coefcients of TiB
2
/Al composite against GCr15 bearing
steel as a function of sliding speed and surface roughness under dry sliding
condition.
Fig. 7. Curves of wear rate of TiB
2
/Al composite against GCr15 bearing steel as a
function of sliding speed and surface roughness under dry sliding condition.
132 S.F. Tian et al. / Materials and Design 53 (2014) 129136
The different variation of tribological properties with surface
roughness was mainly caused by the complexity of tribology.
Under the same surface roughness, sliding speed had little effect
on friction coefcient and wear rate. There was an optimal value of
surface roughness, Ra 0.023 lm, under which friction coefcient
and wear rates reached the lowest value (Figs. 6 and 7). This is in
accordancewiththemassiveexperience of practice, whichis for agi-
ven tribological system, there is an optimal surface roughness to ob-
tain the lowest friction coefcient and wear rate [17].
3.4. Friction mechanism
3.4.1. Analysis of TiB
2
/Al composite
In order to investigate the wear mechanism, worn surfaces of
composite materials were observed, as shown in Fig. 8. For differ-
ent surface roughness the worn surfaces were quite different.
When Ra was 0.606 lm (Fig. 8a), there were obvious traces of
ploughing, indicating a typical two-body abrasive wear, and the
reason was that GCr15 steel disc was rough and harder than
TiB
2
/Al composites, when GCr15 surface asperities sliding on the
surface of composite materials, lots of ploughing appeared, There-
fore, the coefcient of friction and wear rate were high. When Ra
was 0.372 lm (Fig. 8b), worn surface was smooth, but part of it
was covered with the plastic ow of composites, showing the
adhesive wear (showed by arrow). This was the reason why the
friction coefcient was not high, but the wear rate was high. When
Ra was 0.023 lm (Fig. 8c), the worn surface is smooth and no obvi-
ous adhesion, ploughing, showing the lowest friction coefcient
and wear rate. The detail analysis of wear mechanism was in the
next paragraph. Further reduced surface roughness to Ra
0.005 lm (Fig. 8d), there were lots of smearing and delamination
caused by adhesion friction coefcient and wear rate was very
high. Shortly, for Ra 0.606, 0.372 and 0.005 lm, the wear mecha-
nisms were adhesive and abrasive, similar to most reports [1
4,18,19], whereas for Ra 0.023 lm, only similar to Zhaos work
[12]. The variation of fabrication method, volume fraction and test
conditions may give the corresponding interpretation.
Fig. 8. worn surface of composite under the conditions of different surface roughness. (a) Ra 0.606 lm; (b) Ra 0.372 lm; (c) Ra 0.023 lm and (d) Ra 0.005 lm.
Fig. 9. XPS spectrum of worn surface of pin sample under dry sliding condition (Ra = 0.023 lm and V = 1.0 m/s): (a) boron and (b) titanium.
S.F. Tian et al. / Materials and Design 53 (2014) 129136 133
Fig. 10. EDS analysis of worn surface of GCr15 steel disc under conditions of different surface roughness (V = 1.0 m/s) (a) Ra 0.606 lm; (b) Ra 0.372 lm; (c) Ra 0.023 lm and
(d) Ra 0.005 lm.
134 S.F. Tian et al. / Materials and Design 53 (2014) 129136
As seen from Fig. 8c, for Ra 0.023 lm, the wear mechanism was
not adhesive and abrasive wear. In order to determine the wear
mechanism, the worn surfaces were characterized by means of
XPS analysis; the results were shown in Fig. 9.
B
2
O
3
and TiO
2
were observed on worn surface, both of which
were oxidational products of TiB
2
. H
3
BO
3
was also observed, and
self-lubricating, with layered triclinic crystal structure like graph-
ite, MoS
2
, can reduce friction greatly [2022]. The formation of
H
3
BO
3
is from B
2
O
3
reaction with water vapour in the air (B
2
O
3
+ -
H
2
O = H
3
BO
3
), and the reaction is spontaneous [23]. Considering
the smooth worn surface and existence of B
2
O
3
and TiO
2
, for Ra
0.023 lm, the main mechanism was oxidational wear.
There are two resources about boric acid. Firstly, generated in
the frictional process. During sliding, the temperature between
the contact surfaces was high, which can accelerate the tribo-
chemistry reaction of TiB
2
, generating B
2
O
3
and TiO
2
, furthermore
boric acid formed [12]; secondly, introduced by pre-heating. After
pre-heating, there was one 20 nm oxidation layer on the surface of
TiB
2
in composites, constituted of TiO
2
and B
2
O
3
, furthermore
introduced into the composite, as shown in Figs. 2c and 5. And
the thickness of oxidation layer is coincided with the optimum sur-
face roughness (Ra 0.023 lm). Therefore, at the initial frictional
process, the oxidation layer lled with the gap between the asper-
ities of GCr15, weakening the adhesion of aluminium alloy and
GCr15; meanwhile once B
2
O
3
was exposed in the air, H
3
BO
3
was
formed, resulting in low friction coefcient. Oxide introduced by
pre-heating played a part in the running-in stage, and the oxida-
tion of TiB
2
during sliding can keep the low friction at the steady
stage.
When surface roughness was high (Ra 0.606 lm and Ra
0.372 lm), the size of oxidation products generated by pre-heating
were too small to ll the gap between the asperities of GCr15 sur-
face, therefore could not reduce friction. The wear mechanism was
adhesion and abrasion, as veried by Fig. 8a and b. Furthermore,
once the adhesion and abrasion initiated, they would be sustain-
able. Therefore the thin layer (2030 nm) containing B
2
O
3
cannot
reduce friction, and friction coefcients and wear rates were high.
When the surface roughness reduced to Ra 0.005 lm, the mole-
cule-attraction played a major role during sliding, which enhanced
adhesion, and friction coefcient is high, Fig. 8d veried this well.
Ho-Chieh et a. [8] founded that for Si
3
N
4
and SiC, smaller surface
roughness provided smaller friction coefcient in run-in process,
different from the present investigation. It was to be noted that,
the lowest surface roughness they investigated was only
0.092 lm, if they decreased the surface roughness to more low va-
lue, the results may be different.
3.4.2. Analysis of GCr15
The present work is focused on the surface roughness of GCr15
on tribological properties of TiB
2
/AlGCr15 frictional pair. And tri-
bological properties are systematic; therefore the investigation is
very important.
There were two aspects concerning the inuence of GCr15.
Firstly, the hardness of GCr15 was between matrix alloy and
TiB
2
, the asperity on the surface of GCr15 would plough on the
composites during sliding, as shown in Fig. 8a. Meanwhile, TiB
2
would plough GCr15 surface as well. Secondly, the main compo-
nent Fe element in GCr15 is 100% mutual soluble with aluminium
in liquid state [24], Al is adhesive with Fe greatly, which would af-
fect the frictional and wear behaviour.
Element analysis of GCr15 worn surface on the condition of
sliding speed of 1.0 m/s and load of 50 g by EDS was shown in
Fig 10. Fig. 10a presents the worn surface of GCr15 steel disc when
the wear roughness was Ra 0.606 lm. There was adhesive sub-
stance on the worn surface. Surface energy spectrum analysis
showed that aluminium element content was high at the region
of adhesive substance and transferring of elements occurred, indi-
cating the adhesive wear. Fig. 10b gives the worn surface of GCr15
steel disc when the wear roughness was Ra 0.372 lm, EDS was
similar to that of Ra 0.606 lm, showing adhesive wear. Fig. 10c
gives the worn surface of GCr15 steel disc when the wear rough-
ness was Ra 0.023 lm. The worn surface was smooth and adhesive
wear didnt occur. EDS analysis of the surface of GCr15 steel disc
showed that there were mainly Fe, C, and Cr elements (all were
composition of GCr15), no aluminiumelement. Al and Fe were easy
to adhere [24], but adhesion was not observed on the surface of
GCr15 steel disc, therefore we can conclude that the composite
and steel disc were separated from each other by some substance,
combing Fig. 9, the substance was identied as TiO
2
, B
2
O
3
and
H
3
BO
3
. They prohibited the occurrence of adhesive wear. Fig. 10d
presents the worn surface of GCr15 steel disc when the wear
roughness was Ra 0.005 lm. Serious smear could be seen on worn
surface. Aluminium element content is high at this region and
transferring of elements occurred, indicating the severe adhesive
wear occurred. Because the surface was too smooth, the two inter-
molecular interactions between the surfaces played a major role,
resulting in higher friction coefcient and wear rate [17].
4. Conclusions
55 vol.% TiB
2
/2024Al composites were fabricated by pressure
inltration method. Effect of surface roughness was investigated.
Results showed there was an optimal surface roughness (Ra
0.023 lm), the size of which was in the same order of thickness
of oxide layer formed by pre-heating of TiB
2
. During sliding, the
oxide was lled into the asperity gap of GCr15, greatly reduced
adhesion between Al and GCr15, meanwhile H
3
BO
3
was formed,
therefore the friction coefcient and wear rate were low.
Acknowledgements
The microstructure analysis assistance of L.T. Jiang is greatly
appreciated. This work was supported by Program for New Century
Excellent Talents in University (No. NCET-07-0234).
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