Experimental research on friction and wear behavior of dissimilar steel composite structure developed by wire arc-DED process for an automobile brake rotor application

Recent applications of dissimilar composite structures produced through the wire arc-direct energy deposition process are indispensable across various industries due to their lightweight hybrid components and superior mechanical and tribological properties. This process enables a novel way to fabricate of custom-designed, high-performance composite structures that optimize friction, wear resistance, and mechanical characteristics. The present study focuses on developing a dissimilar steel composite structure using wire arc additive manufacturing process, with tribological and microstructural investigations conducted to understand the interfacial wear properties of the alloys. Standardized specimens were prepared to assess their friction and wear behavior through pin-on-disc wear test-rig. Experimental results show that the composite specimens exhibit enhanced wear resistance even under extreme sliding conditions (50 N applied load and 2400 m sliding distance), with tribolayer formation confirmed through FESEM micrographs and EDAX analysis. The highest specific wear rate (SWR) (3.87E-04 mm³/Nm) was observed at 50 N, 6.28 m/s, and 1600 m sliding distance, with a friction coefficient of 0.26. Adhesive wear was identified as the dominant wear mechanism between the specimen and the counterpart. Taguchi's multiresponse optimization indicated that sliding distance had the most significant effect on SWR and friction coefficient, followed by applied load and sliding velocity.