THE EFFECT OF AGE HARDENING TEMPERATURE ON THE

DRY SLIDING WEAR BEHAVIOUR OF A356.0 ALLOY

Prof .Annaiah

Professor, Department of Mechanical Engineering, M.S.Ramaiah Institute of Technology, Karnataka,

Bangalore, India

Research scholar,JNTU Hyderabad, AP,india

Email: - annaiahmh@yahoo.co.in

Dr.Soma v chetty

Principal, Kuppam Engineering College, A P, India

Email: - soma_chetty@rediffmail.com

Dr.Sudheer Prem Kumar

Vice Principal, JNTU College of Engineering, Jagatyala, Hyderabad, AP, India

Email: - bsudheerpk@yahoo.co.in

ABSTRACT

The wear behaviour of as cast and heat treated A 356.0 alloys containing 7.25% silicon slid against
hardened steel counter face were studied using Pin-on-Disc apparatus by varying loads , sliding distances and
sliding velocity. Cast alloys were subjected T6 heat treatment involving solutionisin at 5400deg celg, water
quenching and artificially aged for 6 hrs at three different ageing temperatures namely 170, 180 and 190 deg cel.
The microstructure of both as cast and heat treated alloys were observed using Light Optical Microscope and
photographed. The worn surfaces of Pins were photographed using Light Optical and Scanning Electron
Microscopes to analyze for wear mechanism. Spherodization of needle shaped silicon particles, reduction in size
and their uniform distribution due to heat treatment resulted in improved wear resistance of heat treated alloys
compared to as cast alloys. The wear resistance increased with ageing temperature.

Keywords: Pin-on-Disc, Contact Pressure

 1. INTRODUCTION
Aluminium-Silicon alloys possess light weight,
high specific strength and good heat transfer
ability which makes them suitable materials to
replace components made of ferrous alloys. Al-
Si alloys are widely used in all types of internal
combustion engines such as cylinder blocks,
cylinder heads and Pistons. A356.0 alloys find
applications in aircraft pump parts, aircraft
structure and control parts, automotive
transmission, aircraft fittings, water cooled
cylinder blocks and nuclear energy installations.
Both hypo-eutectic and hyper-eutectic alloys can
be used as useful engine block materials on
account of their adequate wear resistance and
high strength to weight ratio.
There are sufficiently good number of
studies made on tribological behavior of Al-Si
alloys.
However, different researchers have made
studies for different load and speed ranges, test
geometry, test duration, manufacturing
processes, heat treatment process involved, and
environmental factors such as humidity which
make the comparison of results difficult.
Different observations were made by
researchers using different sliding systems.
Different wear mechanisms were observed
during the wear analysis.
A.D. Sarkar (1) R. Shivanath (2) were the earlier
researchers who made studies on a near
eutectic Aluminium-11% Silicon alloy, Al-4 to 20
% Silicon binary alloy and have shown two
distinct wear regimes occurring during sliding
wear namely, (a) mild wear (MW) regime
characterized by low wear rates of 10 -4 mm3/m
to 10-3mm3/m accompanied by the formation of
oxidized tribolayers on the contact surfaces and
(b) a severe wear (SW) regime that existed at
high loads and test speeds called as metallic
wear. K.Razavizadeh and T.S. Eyre (3, 4) have
studied the sliding wear behavior of Al-16% Si
alloy slid against steel counter face and arrived
at the conclusion that there exists an oxidative
wear mechanism. A.B.Gurcan, T.N. Baker (5)
have made studies on the wear resistance of 4,
AA6061 MMC’s together with the monolithic
alloys AA6061 , all in the T6 condition using Pin
on Disc apparatus. AA6061 with Saffil (Al2O3
whiskers) showed little advantage over the
monolithic alloy. But AA6061+ 60% SiC showed
the best performance. Ashok Sharma and T.V.
Rajan (6) made studies on Al-12 Si, Al-12Si-
1Cu-1.5Mg alloy with lead content varying from
4 to 16 % using Pin on Disc apparatus and
have observed a number of wear processes
such as delamination adhesion, abrasion etc
take part in the material removal. The presence
of lead was found to reduce wear and friction.
Mohd Harun, I.A.Talib, A.R.Daud (7) have
studied the effects of Cerium, Zinc, Zirconium
additions and subsequent heat treatment on the
wear of eutectic Al-Si alloy in dry sliding using
Pin on Disc apparatus. Worn surfaces were
investigated using Scanning Electron
Microscope. Studies were also made on binary
Al-Si alloy and LM-13 alloys and compared with
alloys containing Ce, Zn and Zr. The presence
of Mg, Ce, Zn, Zr resulted in age hardening due
to the formation of precipitates which have
improved wear resistance. Further improvement
in wear resistance was achieved by heat
treatment. H.Akbulut, M.Durman, F.Yilmas (8)
studied the wear and friction behavior of LM-13
alloy containing up to 30% Al2o3 fiber against
hard steel counter face with loads 5-60N and
sliding speed of 1m/s. The wear of unreinforced
alloy and composites occurred by groove
formation and its subsequent growth, the
magnitude of which increased with increased
fiber volume and loads. J.An, Y.B.Liu, Y.Lu, Q.Y
Zhang, C.Dong (9) studied the wear behavior of
hot extruded Al-Si-Pb alloy under dry sliding
condition in the temperature range 25-2000C
using Pin on Disc apparatus and have shown
that the microstructure and mechanical
properties can be greatly improved and porosity
can be significantly decreased by hot extrusion.
M.Cai, D.P.Field, G.W Lorimer (10) have studied
both static and dynamic aging of 6061(Al,-
1.34%Mg 2 Si) and 6069(Al-2.25% Mg2Si) aged
at 1700C. Dynamic aging was conducted using
ECAE. It was concluded that dynamic aging
using ECAE is efficient in executing aging
treatment that results in superior mechanical
properties of Al-Mg-Si alloy. Hozimo Goto, Kenji
Uchijo (11) studied Al-Si alloy impregnated with
56% volume of Graphite in various gas
environments to investigate the wear
mechanism. The wear rate was high at low
relative humidity and increased slightly at higher
relative humidity. Dheerendra Kumar Dwivedi
(12) has studied the influence of sliding speed,
load, sliding time and Si content on the inter face
temperature of the wear behavior of Al-8Si alloy
in as cast, melt treated and heat treated
condition and has shown that the wear is closely
related with interface temperature. M.Elmadagli,
T.Perry, A.T.Alpas (13) made studies on three
commercial grades of Al-Si alloys namely, a die
cast 383 with 9.5%Si, a sand cast A390 with
2
18.5%Si and a spray cast alloy with 25% Si
under dry sliding condition and have shown that
an increase in Si content from 9.5% to 25 %
increased the transition load by 140 %. S.K.Dey,
T.A Pery and A.T Alpas (14) have tested Al-
18.5Si alloy against steel counter face for
different sliding cycles up to 2x106 cycles under
boundary lubrication. Ultra mild wear (UMW) in
the alloy occurred due to the abrasive action on
the top of exposed Si particles and fracture of
larger particles. It lasted for very short sliding
cycle (104 cycles). The onset of mild wear (MW)
coincided with complete wearing out of exposed
Si particles. The mild wear damage stabilized
after a prolonged sliding probably due to the
formation of a protective oil residual layer.
Hence, it is observed from literature survey that
the number of studies made on the wear
behavior Al–Si –Mg alloys aged to higher
temperature is less compared to that of as cast
alloys.
Therefore, in the present study, the
effect of ageing temperature on the dry sliding
wear behaviour of A356.0 alloys was made.

2. Experimental details treatment resulting in the solution of soluble

2.1 Materials
A356.0 alloys were sand cast in the
form of cylindrical bars of length 300mm and
diameter 25mm.The chemical composition of the
alloy shown in Table-1 was obtained using
Optical Emission Spectrometer (Baird-Dv6E).
Table I
Chemical composition of A356.0 alloy
(weight %)
Element Weight %
phases to form the solid solution with maximum
concentration of solute in solvent. Quenching
was done to retain super saturation. Age
hardening results in the formation of particles of
second phase in the original phase matrix.
The heat treatment process was carried
out as follows. The alloys were solutionised at
540oC with holding time 9 hours followed by
water quenching (at 600C) and age hardened at
1700C, 180,190o for 6 hours, and these alloys
were designated as where 540-6h-170, 540-6h-
180 ,540-6h-190 ,where 540 represent the
solution temperature and 6h indicate 6hours of
age hardening.

Si 7.25 2.2 Testing Machines

Mg 0.45 2.2.1 Microstructure

The samples for microstructure

Fe 0.086
examination were prepared by following
standard metallurgical procedures, etched in
Cu 0.010 etchant prepared using 90ml water, 4ml of HF,
4ml H2So4 and 2g CrO3 and were examined
Mn 0.018 using Optical Microscope

Ni 0.025

Zinc 0.005

Others 0.028

Al Balance

The conventional heat treatment

adopted for Aluminum alloys is Precipitation Fig 2.1; Optical Microstructure of as cast
heat treatment. A356.0 Alloy

Consisting of solution treatment,

quenching and age hardening. The solution
3
 The micrograph (Fig.2.1) shows the Figs. 3 and 4 shows the
morphology and distribution of the primary microstructures of alloys age
dendrite alpha phase (Aluminum rich phase) hardened for 6h at 1800C and 1900C
in as cast 356.0 alloy which is predominant respectively. A closer examination of
in the matrix. The gray needle shaped the microstructures indicate more
Silicon particles are seen in and around the uniform and better distribution of
inter dendrite regions result in increased spherodised Silicon particles in alloys
aspect ratio. aged to higher temperature compared
to dendrite structure in as cast alloys .

The increased ageing temperature

resulted in spheriodization and more
uniform distribution of reduced size
silicon particles, reduced aspect ratio
and shape factor.

2.3. Hardness test

Fig 2.2; Microstructure of age hardened 540-6h The hardness tests were conducted on
alloy
the alloy as per ASTM E10 norms using
Fig 2.2 shows the microstructure of alloy 540- Rockwell Hardness tester (using 1/16 inch ball
6h-170age hardened to 170 o
C in which more diameter and 100 kg load). The tests were
even distribution of spherodized silicon particles performed at randomly selected places on the
is seen compared to as cast alloy resulting in surface of the samples by providing sufficient
reduced aspect ratio. spacing between indentations and distance from
the edge of specimen. The hardness values of
as cast and heat treated alloys is shown in Table
II

Table II

Alloy Hardness(RHN)
designation

Plate 3: Microstructure of 540-6h-180 alloy As cast 84

540-6h-170 92

540-6h-180 93

540-6h-190 95

2.4 Wear Test

2. 4.1 Wear Testing Machine

Plate 3.4: Microstructure of 540-6h-190 alloy

4
 Fig 5; Wear Testing Machine

Dry Sliding Wear tests were conducted

at room temperature on as cast and alloys age
hardened 3 different temperatures at (i) constant
normal load of 30N and sliding velocity 1 m/s in
sliding distances from 300 to 1500m in steps of
300 m.
A second set of experiments were
conducted using (ii) Normal loads varying from
10N to 60N for a constant sliding distance of
1500 meters.
Fig 7; Optical Micrograph of worn end of as cast
Third set of experiments were alloy under a normal load of 30 N slid for
conducted with 30N load for 10 min for sliding 300meters; Magnification 200X.

velocities 1 to 2.5 m/s.

The wear rates were found by dividing
the loss of weight of specimen by the sliding
distance. The loss of weight was measured
using an Electronic weighing machine to the
accuracy of 0.0001gm. The wear rate was
based on the average value of 5 test results.
During the test, the load was increased
gradually till seizure indicated by abnormal noise
and vibration in Pin -Disc assembly was
observed. The worn surfaces were observed
and photographed using LOM and Scanning
Electron Microscope (JEOL JSM 6490LV)

5
Fig 8; SEM of the worn end of as cast alloy under
a Normal load of 30 N slid for 300meters
Fig 9; Magnified view of the crack formed using
SEM For the worn end of as cast alloy under a
normal load of 30 N slid for 300meters
Fig 13; Optical Micrograph of the Worn end of as
cast alloy under a normal load of 30 N slid for
1500 meter.
Fig 14; Magnified SEM of the Worn end of as cast
alloy under a normal load of 30 N slid for 1500
meter showing the intersecting cracks.
Fig 15; SEM of the worn of as cast alloy under a
normal load of 30 N slid for 1500 meter
showing the grooves and craters.
This is confirmed from the observation of the
worn surfaces of the age hardened alloy (540-
6h) compared to as cast material. The
dimensions of the grooves (length and width)
formed on the worn end of 540-6h are less
compared to as cast alloy. The wear rate was
found to be almost linear between sliding
distance of 300 and900m with a value of
1.86*105gm/meter. A transition in wear rate was
observed at 1200m. Between 1200m and
1500m, the wear was 2.47*10-5 g/m indicating a
33% increase in wear rate.
meters.
alloy under a normal load of 60 N slid for 600
meters.
A similar trend in wear was observed for
age hardened alloy. The optical photograph of
the worn ends of as cast and age hardened alloy
540-6h for a normal load of 60 N is shown in fig
23, 24. It is seen that the width and length of the
grooves formed due to wear are more
pronounced for as cast alloys compared to age
hardened alloys (540-6h). Age hardened alloys
showed better resistance to wear compared to
as cast alloys.
6. References
1.A.D Sarkar.;Wear 31(1975) 331-343
2.R.Shivanath et al; Br Foundry man 70 (1977)
349-356
3.K.Razavizadeh and T.S.Eyre; Wear 79(1982)
325-333
4.K.Razavizadeh and T.S.Eyre; Wear 87(1983)
261-271
5.A.B.Gurcan,T.N.Baker ; Wear 188(1995) 185-
191
6
6.Ashok Sharma and T.V.Rajan; Wear74(1994) 11.Hozimo Gotu,Kenji Uchijo; Wear 259(2005)
217-228 613-619
7.Mohd. Harun, I.A.Talib,A.R.Daud ;Wear 12.Dheerendra Kumar Dwivedi; ISIJ
194(1996) 54-59 International, vol46 (2006) No.7pp1101-1105
8.H.Akbulut,M.Durman,F.Yilmaz ;Wear 13.M.Elmadagli,T.Perry,A.T.Alpas; Wear 262
215(1998 )170-179 (2007) 79-82
9.J.An, Y.B.Liu, Y.Lu, Q.Y.Zhang,C.Dong ;Wear 14.S.K.Dey,T.A.Perry,A.T.Alpas;Wear
256(2004) 374-385 267(2009) 515-524
10.M.Cai, D.P.Field,G.W.Lorimer; Matl Science
& Engg.A 373(2004 ) 65-71

showed better resistance to wear compared to as

10
9 cast alloys for the sliding velocity range
8
7 considered.
6 A s C as t
Wear rate, gm/m

5 5 4 0 -4 h
4
5 4 0 -5 h
3
2 5 4 0 -6 h Light optical Micrographs
1
0
1 1.2 5 1 .5 1 .75 2 2.25
Fig. 3.4. (a,b,c) shows the light optical
S l i d in g V e l o c ity , m /s
micrographs of the worn surfaces of as cast,
peak solution treated and age hardened alloys
Fig. 3.2. As cast versus age hardened alloys tested at a sliding velocity of 1 m/s and the

Fig. 3.2. shows the plot of wear rate verses optical micrographs obtained appear almost

sliding velocity for as cast and age hardened identical with slightly wider and deeper grooves

alloys.A decreased trend in wear rate was observed for as cast material compared to

observed with increase in sliding velocity till a solution treated and age hardened alloys.

critical value of velocity was reached for both as

cast and age hardened alloys.

As cast alloys indicated a 27.3 per decrease in

wear rate between sliding velocities 1and 1.75
m/s reaching a critical value at 1.75 m/s
Fig.3.4a. LOM of worn surface of as cast alloy
.Between 1.75 and 2 m/s, a 6.67% increase in slid at 1m/s
wear rate was observed. The 540-6h alloys

7
 Fig.3.4c. LOM of worn surface of 540-6h -170
alloy slid at 1m/s
In Fig 3.4(d,e,f) are shown the optical
micrographs of worn surfaces at which transition
is observed with comparatively less wider and
deeper grooves compared to Fig 3.4(a,b,c). The
decreased trend may be attributed to a portion of
debris produced filling the grooves on the wear
surface and forming a compact protective layer
of debris at the Pin-Disc interface.
Fig 3.4(g,h,i) shows the optical micrographs of
the worn surface of as cast and heat treated
alloys photographed after transition velocity
resulting in wider and deeper grooves. The
increased wear rate after transition (at high
velocity) may be attributed to steep increase of
temperature at the Pin-Disc interface and sub
surface leading to the softening of Pin material,
irrespective of condition of material (as cast or
heat treated).
Fig.3.4g. LOM of worn surface of as cast alloy
slid at 2.25m/s
Fig.3.4h. LOM of worn surface of 540-6h-170
alloy slid at 2.25m/s
This increased wear rate in as cast material
compared to the other heat treated alloys was
attributed to the low hardeness of as cast
material compared to heat treated alloys. The
other factor resulting in higher wear rate at low
sliding velocity is the metal to metal contact at
the Pin-Disc interface where the rate at which
the material was removed was higher compared
to the rate at which tribolayers are formed at the
Pin-Disc interface.
4. Scanning Electron Micrographs Analysis
Figs.4(a,b,c). show the Scanning Electron
Micrographs of as cast ,peak solution treated and
peak age hardened Al-Si-Mg alloys slid at a
velocity of 1m/s under a normal load of 20 N for
10 minutes.These micrographs are almost
similar with the worn surfaces characterised by
long continuous grooves and severely damaged
regions indicating higher wear rate
.
Fig.4a. SEM of as cast alloy slid at 1m/s
8

Plate 4.39:Light optical micrograph of 540-6h-
170 alloy slid at 1m/s
Plates 4.36, 4.38, and 4.40 shows the
scanning electron micrographs of as
cast ,peak solution treated and peak
age hardened Al-Si-Mg alloys slid at a
velocity of 1m/s under a normal load
of 20 N for 10 minutes.These
micrographs are almost similar with
the worn surfaces characterised by
long continuous grooves and severely
damaged regions indicating of higher
wear rate.
Fig.4f. SEM of 540-6h alloy slid at 2m/s
The Scanning Electron Micrographs are again
almost identical but with lot of striations and
lesser width grooves compared to alloys slid at 1
m/s. The decreased width of the grooves and
lesser damage caused to the surface results in
minimum wear. This decreased wear rate with
increased sliding velocity is attributed to the
increased hardness achieved by heat treatment.
Figs.4(g,h,i). show the Scanning Electron
Micrographs of as cast (slid at 2.25 m/s), peak
solution treated and peak age hardened (slid at
2.25 m/s) under a normal load of 20 N for 10
minutes.

Plate 4.40:Scanning electron micrograph of

Fig.4g. SEM of as cast alloy slid at 2.25m/s
540-6h-170 alloy slid at 1m/sec
The extent of damage casued to as cast surface is
more compared to heat treated alloys.

Figs.4(d,e,f). show the Scanning Electron

Micrographs of as cast alloy (slid at 1.75 m/s),
peak solution treated and peak age hardened
alloys(slid at 2 m/s) under a normal load of 20 N
for 10 minutes.

Fig.4i. SEM of 540-6h-170 alloy slid at 2.25m/s

9
The worn sufaces are charaterized by severe
damage resulting in higher wear rate compared
to wear transition velocity (figs. d,e,f). the wear
rate was maximum for as cast material and least
for 540-6h alloy.

5. DEBRIS ANALYSIS

The debris was carefully collected for as cast 5c

and heat treated alloys at minimum sliding With the increase in sliding velocity to 1.75 m/s
velocity (1m/s), at transition (1.75m/s for as cast at which transition occurred in wear rate, (fig-
and 2m/s for solution and age hardened alloys) d)the major portion of debris produced consisted
and finally at velocity 2.25 m/s for all. The of fragmented shining particles of metal
debris were stored in air tight plastic container removed from the Pin specimen. The quantity of
for SEM analysis. Iron removed from counterface was very small.
when as cast specimen was slid at 1m/s, (refer
fig-a) the debris produced was in the form of
black colored powder clearly indicating the
removal of Iron from the counterface by the
protruded Si particles of the Pin. The large
quantity and bigger size debris produced was an
indication of metal to metal contact at the Pin-
Disc interface. The rate at which the tribolayers
were formed at the interface was lesser
compared to the rate at which the metal was
removed. Refer fig (a) 5d

5e
5a

5f
The debris produced at higher velocity 2.25 m/s
5b (Fig.5g) was a mixture of bigger sized irregular
flakes indicating the occurrence of delamination
of Pin specimen.

10
5g 5i

With further increase in sliding velocity to 2.25

m/s, the quantity of debris produced was more,
compared to vel 2 m/s (Fig.5g)consisting least
quantity of Iron with maximum Pin material
similar to debris observed at 2m/s. For 540-6h
alloy,at sliding velocity of 1 m/s, Fig (5c) the
debris produced consisted of large quantity of
flake like particles with minimum quantity of
5h Iron. At velocity between 2 and 2.25 m/s, (fig
5f&5i) the debris were irregularly shaped
flakes .

Wear rate
Wear Rate of Wear Rate of 540-6h- Wear rate of 540-6h- of 540-6h-
Load,N As cast 170 180 190
10 6.50E-06 4.00E-06 3.47E-06 2.93E-06
20 1.02E-05 6.50E-06 6.53E-06 5.00E-06
30 1.42E-05 8.83E-06 7.53E-06 6.87E-06
40 1.47E-05 1.08E-05 8.47E-06 6.99E-06
50 1.51E-05 1.35E-05 1.09E-05 8.02E-06
60 2.19E-05 1.56E-05 1.31E-05 9.20E-06

Sliding Wear Rate Wear Rate of 540-6h- Wear Rate of 540- Wear Rate of
Distance,m of As cast 170 6h-180 540-6h-190
300 1.28E-05 8.60E-06 3.33E-06 1.70E-06
600 1.43E-05 9.80E-06 7.17E-06 6.03E-06
900 1.52E-05 1.09E-05 8.45E-06 6.57E-06
1200 1.62E-05 1.12E-05 7.67E-06 6.89E-06
1500 1.86E-05 1.45E-05 1.01E-05 9.27E-06

11