Study on Tribological Properties of Al–Al2O3 Composites Prepared Through FDMAIC Route Using Reinforced Sacrificial Patterns

Abstract

In the present work, an attempt has been made to study the tribological properties of Al–Al2O3 composites (under dry sliding conditions) prepared via fused deposition modeling assisted investment casting (FDMAIC) route. Initially, two proportions/mixtures—nylon60%–Al30%–Al2O310% and nylon60%–Al 28%–Al2O312%—were fabricated in the form of fused deposition modeling (FDM) filament on a single screw extruder of L/D 20. Finally, the alternative filaments were used as feedstock filaments of existing FDM system for the fabrication of reinforced investment casting (IC) sacrificial patterns. The effect of process parameters (namely, filament proportion (FP), volume of reinforced FDM pattern, density of FDM pattern (DP), barrel finishing (BF) time, barrel finishing media weight (BFW), and number of IC slurry layers (NSL)) on tribological properties of Al–Al2O3 composites has been studied and optimized using Taguchi L18 OA. Tribotests were performed on pin-on-disk type tribotester at a sliding speed: 239 rpm, sliding diameter-80 mm, load-19.61 N, and time-10 min. Wear was measured both in terms of length and weight loss. Finally, the composites developed were characterized by using optical microscope, scanning electron microscope (SEM), energy dispersive spectroscopy (EDS), and X-ray diffractogram (XRD).