Wear Micromechanics, Mechanisms, and Wear Map of Al–12.6Si–0.25Fe–<i>x</i> Mn Alloy: The Role of Al15(Mn,Fe)3Si2 Intermetallic and Microstructure Modification

Abstract The study investigates the microstructural evolution and wear behavior of Al–12.6Si–0.25Fe–xMn alloys (x = 0, 1, 2, and 3 wt%) in dry sliding wear experiments. Manganese (Mn) considerably modifies the microstructure by modifying primary and eutectic silicon particles, changing Fe-rich intermetallic compounds, and increasing the overall wear resistance of Al–12.6Si–0.25Fe. The microstructural investigation demonstrates the production of Al15(Mn,Fe)3Si2 intermetallic phases, as well as a more uniform Si particle distribution. Wear experiments at varied loads (20 N, 40 N, and 60 N) show that Mn addition significantly reduces wear-rates and specific wear-rates, especially at lower loads. The findings highlight Mn's significance in increasing the hardness and wear resistance of Al–Si–Fe alloys, making them better suited to automotive applications.