Results in mechanical properties and wear behaviour of AA6061-Si3N4 composites

The wear attributes of in-situ stir cast AA 6061-Si 3 N 4 nanocomposites were examined in this study. The composites were made using varied Si 3 N 4 concentrations (3.0, 6.0, 9.0, and 12.0 wt.%) in a metal salt reaction. Optical microscopy and Energy Dispersive X-ray Spectrometry (EDS) were both used to analyse the microstructure of the composite materials. The homogeneous distribution of Si 3 N 4 particles in the AA 6061 matrix was clearly visible in the microstructures. A dry sliding wear test was conducted using a pin-on-disk tester under various time, load, sliding distance, and speed conditions. The composite materials shown better wear resistance than the AA 6061 matrix. Additionally, the wear rate decreased as Si 3 N 4 content increased for all applied loads, sliding distances, and velocities. Due to the incorporation of tiny silicon nitride particles into the matrix and the strong interfacial connection between the in-situ reinforcement and the matrix alloy, the composites showed decreased wear rates. It was revealed that the wear rate of Si 3 N 4 reinforced composites was comparable to that of automotive industry-used cast iron brake drums. According to SEM images, abrasive wear at lower stresses and adhesive wear at higher loads mostly helped in material removal. • In-situ stir cast Al 6061-Si 3 N 4 composites exhibit enhanced wear resistance. • Si 3 N 4 content (3.0 to 12.0 wt.%) improves wear resistance under varied conditions. • SEM/EDS show uniform Si 3 N 4 distribution in the Al matrix. • Wear rate decreases with increasing Si 3 N 4 , comparable to cast iron brake drums. • Abrasive wear dominates at low stresses, while adhesive wear prevails at higher loads.