A New Approach to Evaluating Friction and Wear Behavior of α-β Phase of AA6061 and CuZn37Pb2 under Different Testing Conditions

Wear is a persistent industrial problem caused by the interaction of many interlocking and complex elements. CuZn37Pb2 and AA 6061 are particularly prone to wear due to their numerous industrial applications. To address this problem and contribute to the scientific literature, a comprehensive experimental investigation was conducted to understand and analyze the impact of these interconnected factors. This research developed a dry and lubricated horizontal lathe wear test apparatus. Various parameters, including contact temperature, wear loss, wear rate, and friction coefficient, were compared across different initial surface roughness levels, loads, sliding speeds, wear track diameters, and track widths. Experiments were performed at torques ranging from 25 to 100 N, speeds of 0.30, 0.40, and 0.50 m/s, and wear track diameters of 4, 6, 8, and 10 mm. SEM-EDS, XRD, and optical microscopes were used to examine each sample's worn surfaces and wear tracks. The morphological structure of the sample and the type of test have distinct impacts on the tribological response of the surfaces, each of which interacts uniquely, with influence varying depending on the tribological parameters. Generally, secondary phases (AA 6061) can lead to improved wear resistance due to their harder and more wear-resistant nature compared to the primary aluminum matrix. Conversely, the alpha phase of CuZn37Pb2 is harder and stronger than the beta phase and thus has better wear resistance properties. The error in wear rate calculations is 58.6% in both tests. The findings indicate that the tribological response in ideal laboratory conditions differs from that in actual field environments. This research provided significant insights into understanding and analyzing wear by addressing the largest number of characteristics previously unexplored. Additionally, the findings revealed that while completely eliminating wear is challenging, it can be significantly reduced. Laboratory wear experiments can be extrapolated to field wear tests, offering prototypes for industrial challenges and linking academic research with industry issues.