Materials and Design 32 (2011) 39203925

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Materials and Design

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Dry sliding wear behavior of aluminum based hybrid composites with graphite
nanoberalumina ber
J.S.S. Babu a,, C.G. Kang b,, H.H. Kim c
a

Engineering Research Center (NSDM), Pusan National University, Busan, South Korea
School of Mechanical Engineering, Pusan National University, Busan, South Korea
c
Department of Precision and Mechanical Engineering, Pusan National University, Busan, South Korea
b

a r t i c l e

i n f o

Article history:
Received 5 January 2011
Accepted 25 February 2011
Available online 3 March 2011
Keywords:
A. Compositesmetal matrix
E. Wear

a b s t r a c t
The wear behavior of aluminum based hybrid composites reinforced with graphite nanober (GNF) and
alumina short ber (Al2O3sf) in different volume fraction of bers (10%, 15% and 20%) was studied under
dry sliding conditions. The Taguchi approach to experimental design was used to identify those testing
parameters that have the largest effects on wear loss and coefcient of friction of the composites. Sliding
distance was found to be the prominent parameter affecting wear loss; applied load affected coefcient of
friction most signicantly. The results of Taguchi analysis indicate that wear loss increases with increasing load and sliding distance, but it is reduced with increasing sliding speed. Coefcient of friction
decreases with increasing applied load and sliding speed whereas it increases with increasing sliding distance. The composites with 10 vol.% and 15 vol.% of ber had the lowest wear loss and friction because of
the mixture effect of GNFs and Al2O3sf. However, due to the effect of agglomerated GNFs, there was an
increase in wear loss and friction at 20 vol.%.
2011 Elsevier Ltd. All rights reserved.

1. Introduction
In recent years, hybridization of reinforcements has gained signicant importance in enhancing the properties of Metal matrix
composites (MMCs) [1]. Moreover, mechanical properties of MMCs
are improved by the reduced formation of intermetallic compounds at the interface between bers and the matrix metal that
results from the increase in interfacial area between bers. Currently, aluminum matrix composites with micronano hybrid reinforcements are recognized as promising materials. The MMCs can
show signicantly lower wear rates than unreinforced alloys over
wider ranges of load and sliding speeds. The wear resistances of
MMCs have been found to be improved by hybridization with bers, particles, whiskers and nanoparticles in different combinations [2]. Previously, a few studies on the wear behavior of
hybrid MMCs have been reported. Ames and Alpas [3] studied on
wear mechanisms in hybrid composites of graphitepSiCp/A356
aluminum alloy. They highlighted that wear resistance was improved by hybridization. Zhang et al. [4] found a higher wear resistance for Al/(Al2O3sf + SiCw) hybrid composites than for Al/SiCw and
Al/Al2O3sf composites. Du and Li [5] studied the improvement on
the wear properties of Al matrix by hybridization with the
Al2O3sf/SiCp system. Ahlatci et al. [6] investigated wear behaviors
Corresponding authors.
E-mail addresses: jssbabu@gmail.com (J.S.S. Babu), cgkang@pusan.ac.kr (C.G.
Kang).
0261-3069/$ - see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.matdes.2011.02.064

of Al/(Al2O3pSiCp) hybrid composites produced by pressure inltration. These composites, reinforced with 37 vol.% of Al2O3 and
25 vol.% of SiC particles also contained Mg up to 8%. Metalmetal
and metalabrasive wear resistance were found to increase with
an increase in the Mg content. Tjong et al. [7] found out that the
addition of BN into the Al/SiCp composite system improved the
wear resistance of the latter. Jun et al. [8] developed Al2O3p and
carbon short ber reinforced Al alloy (AlSiCuMgNi) hybrid
composites, by squeeze inltrated route. Fiber normal-orientation
was found to contribute to an improvement in the wear properties.
Long et al. [9] highlighted that composites reinforced with a hybrid
of SiC whisker, SiC particulate, and carbon ber exhibited excellent
wear resistance. Guo et al. [10] studied the tribological behavior of
aluminum/graphitep/SiCp hybrid composites and found that the
wear rate increased as the amount of graphite was increased up
to a threshold value of 5%. Chen et al. [11] found a higher wear
resistance for Cu/CNT composites than for pure Cu matrix, and that
NiPCNT electroless coating exhibited higher wear resistance and
low coefcient than that of the Nigraphite and NiPSiC composites. Choi et al. [12] studied the wear behavior of aluminum based
composites containing CNTs. They found that wear resistance is
enhanced and the coefcient of friction is reduced. Kim et al.
[13] observed that the incorporation of CNTs in the matrix resulted
in a lower coefcient of friction and higher wear resistance.
It may be seen from the above discussions that the composites
have been studied from different combinations of reinforcements

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J.S.S. Babu et al. / Materials and Design 32 (2011) 39203925

Table 1
Properties of Safl alumina bers (ICI, UK) and GNF (Polyeld Korea Co. Ltd.).
Materials

Density
(g/cm3)

Melting
point
(C)

Mean
diameter
(lm)

Mean
length
(lm)

Tensile
strength
(MPa)

Youngs
modulus
(GPa)

Al2O3sf
GNF

3.3
0.2

2000
2800

3
0.05

120
10

2000
3500

300
550

Table 2
Factors and levels for Taguchi method.
Testing parameters

Label

Level 1

Level 2

Level 3

Volume fraction of bers (%)

Applied load (N)
Sliding speed (rpm)
Sliding distance (m)

VF
AL
SP
SD

10
10
240
1000

15
30
360
3000

20
50
480
5000

Table 3
Taguchi L9 orthogonal array design.
Exp. No.

1
2
3
4
5
6
7
8
9

Parameters
Vol.%

Load (N)

Sliding speed (rpm)

Sliding distance (m)

10
10
10
15
15
15
20
20
20

10
30
50
10
30
50
10
30
50

240
360
480
360
480
240
480
360
240

1000
3000
5000
5000
1000
3000
3000
5000
1000

(a)

and matrix on their wear properties. The authors have previously

described the mechanical properties of the Al/GNFs/Al2O3sf hybrid
composites [14], but no systematic attempt has been made to
study the inuence of the hybridization of GNFs and Al2O3sf on
the tribological properties of aluminum based composites. Therefore, in the present work, the wear behavior of Al/GNF/Al2O3sf hybrid composites was analyzed under dry sliding conditions.
Scanning electron microscope (SEM) was used to examine the
microstructures of the worn surfaces, whereas electron dispersive
spectroscope (EDS) was used to analyze the compositions in the
worn surface after being wear tested.

2. Experimental details
2.1. Materials and fabrication of Al based hybrid MMCs
GNFs and Al2O3sf were used as reinforcements for developing a
hybrid preform. Table 1 lists the properties of these bers. A commercial casting-grade aluminum alloy (A356) was used as the matrix material. The experimental set up details of the fabrication of
preform and composites were the same as described elsewhere
[14]. Initially, hybrid preforms were fabricated from GNFs and
Al2O3sf with varying volume fraction of bers such as 10%, 15%,
and 20%. In the rst stage, Al2O3sf and GNFs were mixed in the selected ratio with water and the required amount of binder. The level of mechanical agitation was carefully controlled to avoid the
damage for the short bers and GNFs. Then, cationic polyacrylamide, NaDDBs and starch were xed as (5% each of the total
weight of bers) were added. Subsequently, ultrasonic agitation
was employed for a proper mixing of the additives in the water
medium. The slurry containing bers, binder, ocking agent, surfactant, occulant and water was poured into a rectangular mold.
Water was removed by a vacuum pump. The cakes formed were
pressed by a punch to the desired height. The preforms so formed
were removed from the mold and baked at 100 C. Laboratory scale
hybrid-ber preforms, with dimensions of 55 mm length, 20 mm
width, and 15 mm thickness were thus developed.
The hybrid composite system based on an aluminum alloy
(A356) as the matrix metal using GNFs/Al2O3sf hybrid preform

Table 4
Experimental results.

(b)

Exp. No.

Wear loss (mg)

Coefcient of friction (avg)

1
2
3
4
5
6
7
8
9

0.03
0.05
0.06
0.04
0.03
0.06
0.05
0.06
0.05

0.60
0.58
0.56
0.60
0.56
0.52
0.60
0.62
0.54

GNFs cluster
Table 5
ANOVA for wear.

debonding
Al matrix

Fig. 1. SEM micrographs of Al hybrid MMCs: (a) Al2O3sf dispersed within the Al
matrix and (b) debonding of GNFs cluster and Al matrix.

Factor

DF

S0

VF
AL
SP
SD
Error
Total

2
2
2
2
2
10

0.0002
0.0004
0.0000
0.0006
0.0000
0.0012

0.0001
0.0002
0.0000
0.0003
0.0000
0.0006

7.0
19.0
Pooled
25.0

0.0001
0.0004
Pooled
0.0005
0.0001

P
11.54
34.62
46.15
7.69
100

DF degree of freedom, S sum of squares, V variance, and P percentage of

contribution.

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J.S.S. Babu et al. / Materials and Design 32 (2011) 39203925

0.060

(a)

Wear loss (mg)

0.055

0.050

0.045

0.040

0.035
VF1 VF2 VF3

AL1 AL2 AL3

SP1 SP2 SP3

SD1 SD2 SD3

Parameters
0.60

(b)

Coefficient of friction

0.59

0.58

0.57

Fig. 3. SEM images of worn surfaces of Al/Al2O3sf composites: (a) 10 N and (b) 50 N.
0.56

0.55

0.54

VF1 VF2 VF3

AL1 AL2 AL3

SP1 SP2 SP3

SD1 SD2 SD3

Parameters
Fig. 2. Mean-response graphs: (a) wear and (b) coefcient of friction.

was fabricated by an inltration method. Before the melts were

poured into the preform, the hybrid preform was preheated to
400 C and the mold, which was used to make the MMCs, was preheated to 300 C; preheating deters premature solidication of
melts during inltration. The preheated hybrid preform was placed
in a die and then molten aluminum alloy was poured into the preform. The pouring temperature of the aluminum alloy was in the
650700 C range. It is necessary to maintain the temperature of
the melts above 700 C so that complete inltration is attained;
the full inltration state is essential for improving the mechanical
properties of the MMCs. A pressure of 5 MPa was applied using a
punch velocity of 7 kN/s. The aluminum melt was successfully
inltrated into the hybrid preform for volume fractions of 10%,
15%, and 20%.
2.2. Wear test
Wear tests were performed using a pin-on-disc type wear machine (PLINT TE-92-UK) at room temperature. The specimens in
the dimension of 18  8 mm, and both sample and counterface
were ultrasonically washed in acetone before tests. A stainless
steel (SUS-304) with a diameter of 48 mm was used as a counterpart. The initial weight of the specimen was measured in an electronic weighting machine with an accuracy of 0.001 g. The
friction coefcient was continuously measured during the test.
The morphologies of the worn surfaces were examined using
SEM, whereas the compositions in the specimens after wear testing

were analyzed using EDS. Taguchi methods of experimental design

provide a simple, efcient and systematic approach for the optimizing testing parameters and nding out their contribution on
target parameters. The testing parameters were volume fraction
of bers (VF), applied load (AL), sliding distance (SD) and sliding
speed (SP), and the target parameters were wear loss and coefcient of friction. The four process parameters were studied at three
levels, as shown in Table 2. The experiments were carried out under the conditions given in Table 3; three experiments were conducted for each trial. In the Taguchi method, a design parameter
is considered signicant if its inuence is large compared with
the experimental error as estimated by the analysis of variance
(ANOVA) statistical method. Mean-response graphs were plotted
using ANVW-31 software and the percentage of contribution of
testing parameters was determined by ANOVA analysis.
3. Results and discussion
3.1. SEM analysis of hybrid MMCs
SEM observations, conrmed that Al2O3sf is well dispersed
within the matrix metals (Fig. 1a). However, GNFs show a tendency
to agglomerate within the matrix metals but to different extents.
Although GNFs exist as clusters, their distribution within the array
of Al2O3sf network is found to be relatively good, and the Al melts
inltration into the GNFs cluster (Fig. 1b). The formation of debonded surface is due to the poor wettability between the Al matrix
and GNF (carbon) [15].
3.2. Inuence of testing parameters on wear loss
Table 4 gives the experimental results of wear loss and coefcient of friction of the samples. Results of the pooled ANOVA for
wear loss are shown in Table 5. Fig. 2a shows the mean-response
graphs of the inuence of the various testing parameters on the
wear loss of the MMCs. The inuence of interactions between the
parameters is not considered here. It has been found that wear loss

J.S.S. Babu et al. / Materials and Design 32 (2011) 39203925

decreases when volume fraction is increased from 10% to 15% and

then to 20%. The percentage of GNFs may be responsible for the increase in wear loss because GNF agglomerates can weaken the
interfacial bonding between Al2O3sf and the matrix metal. This enhances slip between short bers and GNFs within matrix metal
which can lead to a higher wear loss. It has been observed that
wear loss increases with the increase of the applied load and sliding distance, which indicates more removal of materials from the
surface. In addition, wear loss decreases with an increase in the
sliding speed due to the formation of a mechanically mixed layer
(MML), thus reducing wear by covering more area of contact. The
ANOVA table shows the contributions of the testing parameters
of volume fraction of bers, applied load, sliding speed, and sliding
distance to be 12%, 35%, 8% and 46%, respectively. Thus, sliding distance has been found to be the most inuential testing parameter
controlling wear loss. At lower loads the composite with 15%
shows better wear resistance compared with other conditions
(i.e., 10% and 20%).

3.3. Inuence of testing parameters on coefcient of friction

3923

friction decreases as the volume fraction increased up to 15 vol.%.

When the volume fraction of bers is above 15%, the friction shows
an increasing trend due to the presence of aluminum carbide within the GNF agglomerations, which weakens the worn surfaces [16].
Abrasion by the decohesion of GNF agglomerates causes a contact
between the matrix and counter face; as a result, the surface
roughness, hence the coefcient of friction, increases. It is evident
from the gure that friction decreases as applied load and sliding
speed are increased for all the conditions, as expected. In the case
of 15 vol.% and 20 vol.%, however, the friction remains almost
invariant with sliding speed. The coefcient of friction has been
found to increase with an increase in the sliding distance, but the
friction remains unchanged up to 15 vol.% of bers. Table 6 shows
the result of the ANOVA for friction indicating that the contribution
of volume fraction of bers, applied load, sliding speed, and sliding
distance to be 12%, 68%, 4%, and 15%, respectively. Therefore, applied load was the most signicant factor inuencing the coefcient of friction of the composite, while volume fraction of ber
and sliding distance had a slight effect.
3.4. Wear worn surface analysis

Fig. 2b shows the mean-response graphs for the inuence of

testing parameters on the coefcient of friction. The coefcient of
Table 6
ANOVA for coefcient of friction.

Typical SEM images show the wear worn surfaces of the composites reinforced by alumina short bers after testing at 10 N

(a)
0

Factor

DF

VF
AL
SP
SD
Error
Total

2
2
2
2
2
10

0.0012
0.0060
0.0001
0.0014
0.0001
0.0088

0.0006
0.0030
0.0000
0.0007
0.0000
0.0043

13.0
67.0
Pooled
16.0

0.0011
0.0059
Pooled
0.0013
0.0004

12.37
68.04
15.46
4.12
100

DF degree of freedom, S sum of squares, V variance, and P percentage of

contribution.

(b)

(c)

Fig. 4. SEM images of the worn surfaces of Al/GNF/Al2O3sf composites (10 vol.%): (a)
10 N and (b) 50 N.

Fig. 5. SEM images of the worn surfaces of Al/GNF/Al2O3sf composites (15 vol.%): (a)
10 N, (b) 50 N, and (c) EDS analysis of Fig. 5a.

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J.S.S. Babu et al. / Materials and Design 32 (2011) 39203925

(a)

(b)

GNFs cluster

(d)

(c)

(e)
Fig. 6. SEM images of the worn surfaces of Al/GNF/Al2O3sf composites (20 vol.%): (a) 10 N, (b) 50 N, (c) GNFs agglomeration, (d) entrapment of wear debris, and (e) EDS
analysis of Fig. 5c.

and 50 N (Fig. 3a and b). It is clearly seen that wider grooves on the
worn surface due to abrasive wear, as a result, the wear loss is
higher. Fig. 4a and b shows typical SEM images of the worn surfaces of hybrid composites with 10 vol.% at 10 N and 50 N. Compare with alumina reinforced composites, a smoother worn
surface was obtained by adding GNFs. Moreover, reattachment of
wear debris on the worn surfaces due to higher applied load can
be clearly seen. Fig. 4a shows the worn surface of composites
tested at 10 N; a slight ploughing can be observed. This is believed
to be the result of abrasion by bonding of alumina bers and GNFs
within the metal matrix. The material delamination is not severe
on the sample tested under lower load (Fig. 4b), i.e., the grooves
are ner. The increase in applied load resulted in severe plastic
deformation of worn surface in the sliding direction [17]. However,
severe plastic deformation was not observed in the present composite system, because of the presence of GNFs.

In the case of hybrid composites with 15 vol.% at 10 N and 50 N

(Fig. 5a and b), the ne ploughing grooves were observed in the
wear-tested specimen. This indicates the removal of material by
delamination and a mild damage of wear surface in the composite
found. The plastic deformation of matrix can be restricted due to
the presence of GNFs, which act as a barrier to the movement of
dislocation, resulting in higher wear resistance. Fig. 5b shows the
worn surface of the composites tested at 50 N; the grooves are ner and formed smaller debris on the worn surface. At a higher
load, a large extent of material ow and a scufng tendency have
been observed. This leads to the smoother worn surface and higher
degree of sliding action, which results in a reduction of coefcient
of friction. The reattachment of wear debris can also be seen in the
worn surface. The adhesive and abrasive wear of the hybrid composites is slighter than that of the mono-composites due to the
presence of GNFs, which act as self-lubrication material; this effect

J.S.S. Babu et al. / Materials and Design 32 (2011) 39203925

is induced by carbon and it reduces the coefcient of friction [18].

Generally, materials having hexagonal structure are low shear
strength. GNF has a hexagonal structure, hence a low shear
strength, and therefore low coefcient of friction.
Fig. 5c shows the EDS analysis of the worn surface after being
wear tested. The larger amount of Fe in the worn surface of composites might be further evidence of a higher degree of abrasive
wear for 15 vol.%. It indicates that the Fe transfer layer prevents
contact between the surfaces, hence enhancing the wear resistance
[19]. In addition, the formation of Fe transfer layers is the delay of
mild to severe wear transition. The small peaks in the prole can
be due to the presence of aluminum carbides.
Fig. 6a and b shows the SEM images of worn surfaces of composites with 20 vol.% at 10 N and 50 N. It can be clearly seen that
the worn surface was smeared layer due to scufng, and delamination is more on the surface of the sample tested under lower load.
Furthermore, the scar of plastic deformation by ploughing and the
worn surface was severely deformed. Normally, in the worn surface, micro-cracks and voids are induced due to the plastic formation of composites. At higher load there were no signs of the
formation of grooves in the worn surface, but it seems that in some
regions agglomerated debris were formed, suggesting that the
strain hardening effect induces debris and severe deformation on
the surface by ploughing [20]. At higher magnication the worn
surface indicates the presence of agglomerated GNFs debris
(Fig. 6c), which appear to be bonded within the worn surface.
Fig. 6d shows the detachment of wear debris due to microcrack
and weak bonding between the GNFs cluster and metal matrix,
and it is entrapped within the worn surface. The failure occurred
only after the accumulation of micro-cracks of bers.
Based on EDS analysis of the worn surfaces as shown in Fig. 6e,
the absence of iron indicates that the materials transition by adhesion did not take place. In the prole a small peak can be observed;
this may be presence of the aluminum carbide, which weakens the
worn surface, as previously mentioned. In all tested samples, the
presence of carbon found in the surface of the analyzed region
seems to indicate the presence of GNF. The ber fragmentation effect was not observed in the present hybrid composite system due
to the higher applied load while wear testing. Generally, this effect
occurs when the applied load is low, hence no plastic deformations
occur in the worn surfaces [6]. This is due to the decreased degree
of abrasive wear mechanism.
4. Conclusions
In the presently developed aluminum based GNFs/Al2O3sf hybrid composites, the wear loss and coefcient of friction were lower at 15 vol.%. This has been accounted for in terms of the better
load bearing from the matrix to the Al2O3sf in the presence of GNFs,
and also delays in the fracture of alumina ber. The composites
above 15 vol.% exhibit an increase in the wear loss and friction.
This has been attributed to the dominant action of agglomerated
GNFs and aluminum carbide within the metal matrix. Worn surface examination of the composites revealed the formation of an
Fe layer, which can lead to higher wear resistance. The Taguchi

3925

design of experiment was used to evaluate the contribution of testing parameters to the wear loss and friction of the composites. The
prominent testing parameter for the wear of the composites has
been found to be the sliding distance, but applied load and volume
fraction of ber have slight inuence on wear loss. Applied load
was found to affect the coefcient of the composites
predominantly.

Acknowledgments
This work was nancially supported by the National Research
Foundation of Korea grant funded by the Korea government
(MEST-No. 2009-0081077) and Postdoc-2010, Pusan National University, Busan, South Korea.
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