Impact of Using Tungsten, Cobalt, and Aluminum Additives on the Tribological and Mechanical Properties of Iron Composites

Abstract

The effect of tungsten, aluminum, and cobalt on the mechanical properties of iron-based composites prepared by powder technology was studied. Five samples with different contents of tungsten, aluminum, and cobalt were established. The five samples have the following chemical compositions: (I) full iron sample, (II) 5wt.% tungsten, (III) 5wt.% tungsten-4wt.% cobalt-1wt.% aluminum, (IV) 5wt.% tungsten-2.5wt.% cobalt-2.5wt.% aluminum, and (V) 5wt.% tungsten-1wt.% cobalt-4wt.% aluminum. The mixed composite powders were prepared by mechanical milling, in which 10:1 ball to powder ratio with 350 rpm for 20 h was cold compacted by a diaxial press under 80 bars, then sintered at temperatures ranging from 1050 °C to 1250 °C in an argon furnace. The samples were characterized mechanically and physically using XRD, SEM, a density measuring device, a hardness measuring device, a compression test device, and a tribological device for wear and friction tests. XRD results refer to the formation of different intermetallic compounds such as Fe7W6, Al5Co2, Fe2W2Co and Co7W6 with the main peaks of Fe. The good combination of tribological and mechanical properties was recorded for sample number five, which contained 5% W, 4% Al, 1% Co and Fe base, where it obtained the highest wear resistance, largest hardness, acceptable compressive strength, and lowest friction coefficient due to the good combination of hard and anti-friction intermetallic action compared with the other samples. This sample is a good candidate for applications which require high wear resistance and a moderate friction coefficient accompanied with high toughness, like bearing materials for both static and dynamic loading with superior mechanical and tribological properties.