Tribological behavior of high-volume-fraction SiCp/6092Al composites under different loading conditions

Abstract High-volume-fraction SiCp/6092Al composites exhibit significant potential for applications in aerospace, automotive manufacturing, and precision instrumentation, attributable to their exceptional lightweight characteristics, high strength, excellent thermal conductivity, and wear resistance. This study systematically examines the tribological behavior and surface damage evolution mechanisms of a 55% volume fraction SiCp/6092Al composite under loads ranging from 20 N to 50 N. The results demonstrate that the friction coefficient increases markedly from 0.388 to 0.475 as the load rises from 20 N to 30 N, stabilizing thereafter. The wear volume displays a linear relationship with load, peaking at 0.033 mm 3 at 50 N. Microstructural analysis indicates that, at a low load of 20 N, the wear scar surface remains relatively smooth, exhibiting only minor scratches. In contrast, at a load of 50 N, the wear depth and width increase by 3 times and 1.6 times, respectively, compared to the 20 N condition, signifying accelerated surface damage. At the high load of 50 N, the wear scar area reveals numerous deep grooves and material spalling. This study elucidates the critical load effect and the evolution of tribological properties in high-volume-fraction SiCp/6092Al composites, thereby providing essential theoretical foundations and practical guidance for the design and engineering of new high-performance aluminum-matrix composites.