Wear characterization of rare earth-based metal matrix composites reinforced with alumina and SiCp particles

Purpose Manufacturing structural components such as blocks, bearings and bushes necessitate materials with superior wear and corrosion resistance to enhance performance and durability. This study aims to develop and analyse rare earth-based metal matrix composites (MMCs) reinforced with alumina (Al 2 O 3 ) and SiCp particles to meet these requirements. Design/methodology/approach A novel composite is fabricated by adding cerium oxide (CeO 2 ) to an Al6063 alloy matrix reinforced with Al 2 O 3 and SiCp particles in varying proportions using the stir casting method. The mechanical properties of the composite are evaluated by conducting hardness tests. Dry sliding wear behaviour is investigated using a pin-on-disc apparatus, considering sliding distance, applied load, composition percentage and sliding speed as input parameters. Response surface methodology is employed to model the wear behaviour, and regression analysis is performed to establish correlations between process variables and wear rate. The model is validated through confirmatory experiments. Findings Response and contour plot analysis indicate that sliding speed and sliding distance significantly influence the wear rate. The results from main and interaction plots support these findings. Analysis of variance results confirm that sliding speed and sliding distance consistently impact wear behaviour. Furthermore, SEM analysis of the samples with the highest and lowest wear rates provides insights into wear mechanisms. Originality/value This study contributes to the development of high-performance structural materials by incorporating rare earth elements into MMC to enhance wear resistance. The findings offer valuable insights into optimizing wear behaviour through process parameter adjustments, making the composite suitable for structural applications requiring superior durability.