Abrasive wear behavior of Al–WC nanocomposites produced by ultrasonic stir casting

Wear-resistant lightweight materials are increasingly required in aerospace, automotive, and other engineering applications to enhance component durability, improve energy efficiency, and extend service life under severe operating conditions. Aluminum matrix nanocomposites reinforced with ceramic nanoparticles have emerged as promising candidates owing to their superior mechanical properties and enhanced wear resistance. In this context, the present study investigates the abrasive wear behavior of Al–WC nanocomposites fabricated using an ultrasonic vibration-assisted mechanical stirring process, which promotes the homogeneous dispersion of WC nanoparticles within the aluminum matrix. Pin-on-disc tribological testing against 400, 600, and 800 grit SiC abrasives under standardized conditions (10–40 N normal load, 0.4 m/s sliding speed, and 5 min test duration) reveals that the Al–2 wt.% WC composite exhibits the best wear performance, showing approximately 40%–50% lower wear than the base alloy under identical testing conditions. Nano-indentation tests conducted on the base alloy and WC-reinforced composites reveal that the elastic modulus increases from 105 to 120 GPa with the addition of 0.5 wt.% WC; however, a further increase in WC content reduces the elastic modulus to 69.7 GPa at 2 wt.% WC. The wear rate decreases consistently with increasing WC content across all applied loads and abrasive grit sizes. At a normal load of 10 N, the wear rate decreases from approximately 3.1 × 10 −6 for the base alloy (400 grit) to approximately 1.0 × 10 −6 for the Al–2 wt.% WC composite, corresponding to an approximately 68% reduction in wear rate. SEM/EDS characterization of the worn surfaces and wear debris identifies abrasion by SiC particles, adhesive material transfer, and delamination caused by subsurface cracking as the dominant wear mechanisms. Overall, the homogeneous dispersion of WC nanoparticles significantly enhances the abrasive wear resistance of the aluminum matrix composite by minimizing surface damage, demonstrating its potential for demanding tribological applications.