Tribological Behaviors and Statistical Experimental Design of Sintered and Age-Hardened Aluminum–Copper Based Composites

This paper reports on the influence of various processing parameters and different SiCp proportions on the outcome of mechanical, tribological, microstructural, and microcompositional investigations of Al-Cu based composites used as potential brake friction materials for eco-friendly vehicle parts. The composites were obtained by powder metallurgy, and then the sintered composite was treated at 515 ± 5 °C/6 h, quenched in water, and artificially aged at different temperatures and times. The microstructural and microcompositional investigations of the composites were made using an environmental scanning electron microscopy (ESEM), energy-dispersive X-ray spectroscopy (EDS). After analyzing the microstructures in correlation with the results of the hardness tests, the optimal proportion of SiCp and optimal heat treatment parameters were determined. The composite samples with the best properties were chosen for tribological investigation. The friction and wear tests of samples were made under dry sliding conditions using a “pin on disc” machine, at a contact pressure of 0.35 to 1.15 MPa, 2 to 4.5 m/s relative speed, and the prediction of tribological behavior was made using a linear factorial design approach.