Article
Evaluation of Mechanical and Wear Properties of Al
5059/B4C/Al2O3 Hybrid Metal Matrix Composites
Uppu Pranavi 1 , Pathapalli Venkateshwar Reddy 1, * , Sarila Venukumar 1 and Muralimohan Cheepu 2, *






Citation: Pranavi, U.; Venkateshwar
Reddy, P.; Venukumar, S.; Cheepu, M.
Evaluation of Mechanical and Wear
Properties of Al 5059/B4 C/Al2 O3
Hybrid Metal Matrix Composites. J.
Compos. Sci. 2022, 6, 86. https://
doi.org/10.3390/jcs6030086
Academic Editor: Konda
Gokuldoss Prashanth
Received: 3 February 2022
Accepted: 7 March 2022
Published: 9 March 2022
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Copyright: © 2022 by the authors.
Licensee MDPI, Basel, Switzerland.
This article is an open access article
distributed under the terms and
conditions of the Creative Commons
Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
J. Compos. Sci. 2022, 6, 86. https://doi.org/10.3390/jcs6030086
1 Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderabad 501218, India;
upranavi908@gmail.com (U.P.); venukumar24@gmail.com (S.V.)
2 Department of Materials System Engineering, Pukyong National University, Busan 48513, Korea
* Correspondence: mr.pvreddy@gmail.com (P.V.R.); muralicheepu@gmail.com (M.C.)
Abstract: There is a developing interest in efficient materials in automobile and aerospace fields
that involves the improvement of metal matrix composites (MMCs) with great properties which
incorporate higher strength, hardness and stiffness, better wear and destructive resistance along with
better thermal properties. This work deals with the evaluation of the mechanical and wear properties
of the newly developed hybrid MMC of Al 5059/B4 C/Al2 O3 produced by stir casting method. The
main aim of the work was to evaluate the mechanical properties of various MMCs fabricated with
various weight proportions of ceramic particles (B4 C and Al2 O3 ). An increase in the tensile strength
and the surface hardness was observed with the increase in the ceramic particles but there was
a decrease in the percentage of elongation of the specimen. An increase in the ceramic content in the
composite samples made the composite sample brittle (composite) from ductile (base metal).
Keywords: Al-5059; ceramic materials; HMMC; hardness; tensile strength; wear; SEM
1. Introduction
The increasing demand for fuel-efficient vehicles in the automotive industry along
with the reduction in energy consumption and air pollution took a step forward with the
development of MMCs. MMCs are the engineered combination of metal matrix material
and reinforcement particles, and have upgraded features like as high strength, very light
weight, stiffness, excellent wear resistance and oxidation, and exhibit better corrosion
resistance. All these tailored properties increase the use of MMCs in marine, aviation,
electronics, nuclear and automobile industries. Hybrid metal matrix composites (HMMCs)
are also a wide area of research at present [1–3]. HMMCs exhibit fracture toughness and
the ability to withstand corrosion conditions at high temperatures. All these properties
are easily achievable with MMCs/HMMCs of aluminum rather than other light-weight
magnesium and monolithic titanium alloys. Additionally, the low-cost fabrication, high
strength and corrosion resistance of aluminum make wide usage of the metal in many
engineering applications practically. The composites made of Al and Al2 O3 have efficient
mechanical as well as tribological properties and as such they can be widely used in
motor blocks and crank bearings, which improves the wear resistance [4–7]. Fatigue
resistance, which is the most important and essential property for automotive applications,
is obtained by using Al-MMCs. An increase in the mechanical strength and wear resistance
of aluminum can be obtained when ceramic particles, like B4 C, ZrSiO4 , etc., are used for
reinforcement. The composites made from particulate metal matrix comprise isotropic
properties. The mechanical properties of the metal matrix composite depend on some
important factors that comprise the size and weight fraction of the particulates and the
method of developing the composite [8–11].
The fabrication technique adopted in the present work is considered on the basis
of the work done by Bansal and Saini [12]. In their work, the stir casting process is
considered simple, flexible and economical. Fabricated specimens of Al359 alloy with
https://www.mdpi.com/journal/jcs
J. Compos. Sci. 2022, 6, 86 2 of 13

variable wt% of SiC and SiC/graphite were investigated for tensile strength, wear resistance
and surface hardness. The specimen with higher wt% of SiC/Gr exhibited improved wear
and hardness properties, superior tensile strength and a continuous decrease in elongation
and ductility. Reddy et al. [13] studied the influence of the substitution of carbides of
silicon and titanium to the metal matrix of Al5052 and observed the enhancement of the
mechanical properties of the aluminum alloy. The increase in the wt% of the TiC has
gradually reduced the wear of the composite. A steady dissemination of carbide particles
and a reduction in voids and grooves are observed from the SEM images. Reddy et al. [14]
correlated the experimental work done by using BBD (Box–Behnken design) of RSM
with the predicted results, verified with ANOVA, to obtain the optimum specific wear
rate of Al6063/TiC MMC. Daniel et al. [15–17] explained clearly the experimental work
and the procedure for identifying the optimal conditions for the improved behavior of
composites like Al5059/SiC/MoS2 . Several of the suggested control factors such as the
weight percentage (wt%), sliding speed and load are adopted in the present work. The load,
wt% of SiC and sliding velocity influence the wear resistance of the composites as revealed
from the research work. The Taguchi technique was applied and 27 tests conducted on
Al5059/SiC MMC, and the optimum conditions were analyzed using ANOVA. The study
included the stir casting process for the fabrication of the composites and the use of SEM
images to observe the worn-out surface of three different fabricated specimens. The results
depicted that out of samples of 5, 10 and 15 wt% of SiC in aluminum alloy 5059, the
specimen with highest wt% of SiC showed dominant tribological behavior and better wear
resistance at a particle size of 10 µm. The maximum material removal rate and minimum
surface roughness was also obtained by the best combination of various parameters.
Joseph et al. [18] reviewed various processes and suggested stir casting as the best
and most economical method to fabricate the composites. The study included obtain-
ing the optimized process parameters to improve the behavior of the composite formed
using Al7075 as base metal and various wt% of SiC and TiB2 as reinforcement particles.
Lawate et al. [19] studied the process parameters influencing the stir casting process to
observe the behavior of alloys of aluminum when reinforced with Al2 O3 . Mohan et al.’s [20]
research work included the analysis of several mechanical properties of Al6061/B4 C/Gr
composite in which the constituents are added based on constant volume ratio. With
the description of the characteristics of the aluminum alloy, carbide and graphite used,
the study explained the improvement in hardness and toughness with the inclusion of
B4 C and the increase in tensile strength with the proportionate increase in the graphite
wt%. James et al. [21] studied the hardness, tensile strength and tribological properties of
an Al6061/ZrO2 /Al2 O3 composite. The specimens were fabricated using the stir casting
method. The study reported an increase in the tensile strength, hardness and wear resis-
tance along with the dissimilate distribution of the particulate constituents. Ajith et al. [22]
observed that an artificial neural network model gives most convincing results to obtain
the required properties of the composites by forecasting the optimal input parameters. The
work was carried out on machined composite specimens of Al5052/SiC with a constant 2%
of MoS2 . Suraya et al. [23] explained the effect on composite materials due to the variation
of the wt% of reinforcement particles in the aluminum alloy. It was observed that there
was gradual enhancement in the properties of the aluminum alloy composite if the wt%
of TiC was between 0 and 10. Further increases of wt% of TiC resulted in a diminution of
various significant properties of the alloy. The research work on MMCs exhibited various
fabrication processes to develop the composite specimens and various analysis techniques
to obtain optimized parameters that enhance several properties of the base metal for their
application in numerous engineering fields [24]. Several researchers worked on titanium-
based composites as well [25–28]. Zherebtsov et al. [25] explained the effect of hot rolling
on the mechanical properties of the prepared titanium-based MMCs. Their work concluded
that there is a substantial improvement in ductility at elevated temperature of up to ~12%
elongation. The increase in ductility of the prepared MMCs is due to the presence of a more
stable α phase in the hot rolled condition.
J. Compos. Sci. 2022, 6, 86 3 of 13

Koo et al. [26] worked on TiB-reinforced titanium alloy composites fabricated using
a spark plasma sintering process. The effect of TiB’s whiskers aspect ratio on the strengthen-
ing efficiency was studied in their work. Finally, the work concluded that the 58 aspect ratio
whiskers obtained better strengthening efficiency when compared to the other aspect ratio
whiskers. In another work of Chen et al. [27], the authors worked on the aspect ratio effect
with regard to the strengthening of an aluminum-based metal matrix composite reinforced
with carbon nano tubes. The work concluded that the prepared composites obtained better
strength irrespective of the CNT aspect ratio.
The improvement in the physical, mechanical and tribological properties of different
aluminum alloys depends on the percentage of reinforcement particles in the fabricated
composite. Based on the above literature, the present work deals with the evaluation of
the tensile strength, hardness and wear resistance of fabricated hybrid MMCs. Aluminum
oxide improves physical and mechanical properties like tensile strength and hardness,
whereas boron carbide improves the erosion resistance of the composite sample. The main
aim of the present work is to fabricate hybrid MMCs to improve the dry sliding wear
resistance and mechanical properties. The present study includes the evaluation of the
effect of wear parameters like sliding speed, load and reinforcement content (B4 C and
Al2 O3 ) on wear properties. Bonding among the particles and matrix material was studied
by scanning electron microscopy of the fractured and wear-tested MMC. Based on the
results obtained, that the developed composites can be used as an innovative standpoint in
enhancing the properties of composites for aerospace and automotive applications.

2. Materials and Methods

2.1. Fabrication of Composite
The metal matrix composite (MMC) was fabricated by using an ultrasonic-probe-
(USP)-assisted stir casting technique. The fabrication of the composite specimen was
carried out using Al-5059 as the metal matrix material and the ceramic materials Al2 O3 and
B4 C as reinforcement particles. The chemical composition of Al-5059 is shown in Table 1.
From previous research, it was understood that there is an improvement in the physical
and mechanical properties of composite materials when the percentage of reinforcement
particles in a composite material is below 20% [24]. However, this results in a decrease in
some properties, like ductility, making the composite unsuitable for some manufacturing
processes, like forming. Thus, to keep the composites able to be used in any manufacturing
methods, the maximum weight percentage (wt%) of the reinforcement material is 15%
in the present research work. In this work, the wt% of reinforcement particles in each
of the three fabricated composites was 5%, 10% and 15%. The fabrication procedure for
HMMCs has been explained clearly in the literature [24,29,30]. The selected reinforcements
were preheated to 500 ◦ C initially. The matrix material Al-5052 was stir cast to 800 ◦ C;
once the matrix material is completely converted to liquid form, the required amount of
reinforcement quantity (pre-heated) was added into the matrix by continuously stirring
and sonicating from the bottom. The three specimens fabricated by varying the wt% of
ceramic particles and the metal matrix are tabulated and shown in Table 2. The fabricated
composite specimen samples are shown in Figure 1.

Table 1. Chemical composition of Al5059.

Element Si Fe Cu Mg Ti Mn Cr Al
Weight Percentage ≤0.45 ≤0.50 ≤0.25 5–6 ≤0.20 0.60–1.2 ≤0.25 89.8–94
J. Compos. Sci. 2022, 6, 86 4 of 13

Table 2. wt% of the composite materials in each specimen.

Specimen
Al5059 (wt%) B4 C (wt%) Al2 O3 (wt%)
Designation
SP 1 95 2.5 2.5
SP 2 90 5 5
J. Compos. Sci. 2022, 6, x FOR PEER REVIEW 4 of 13
SP 3 85 7.5 7.5

Figure 1.
Figure 1. Fabricated
Fabricated hybrid
hybrid composite
composite sample
sample using
using stir
stir casting
casting process.
process.

2.2.
TableInvestigation
1. Chemicalon MechanicalofProperties
composition Al5059.
TheElement
hardness test and the
Si tensile
Fetest for
Cudetermining
Mg the mechanical
Ti Mn properties
Cr were
Al
conducted on three fabricated HMMC specimens. The procedures adopted to conduct
Weight Percentage ≤0.45 ≤0.50 ≤0.25 5–6 ≤0.20 0.60–1.2 ≤0.25 89.8–94
these mechanical tests are clearly explained below.
Table
2.3. 2. wt% of
Hardness the composite materials in each specimen.
Test
The surface of the composite specimens was polished with emery paper. The speci-
Specimen
Al5059 (wt%) B4C (wt%) Al2O3 (wt%)
mensDesignation
were then used for obtaining the Brinell’s hardness number using a Brinell hardness
tester. TheSPthree
1 composite samples95 were tested based on
2.5 ASTM E384 [31] standards.
2.5
SP 2 90 5 5
2.4. Tensile Test
SP 3 85 7.5 7.5
The tensile strength of the HMMC specimens was tested using a computer-operated
universal tensile on
2.2. Investigation machine, (UTM)
Mechanical INSTRON-3369, with a capacity of 50 kN. A crosshead
Properties
speed of 0.5 mm/min at room temperature was applied to the composite specimens. The
The
tensile hardness
test test and the
on the composite tensile test
specimens wasforconducted
determining the mechanical
as per properties
ASTM E8 [32] were
standards.
conducted on three fabricated HMMC specimens. The procedures adopted to conduct
these
2.5. mechanical
Wear Test tests are clearly explained below.
The procedure for the wear test has been explained in detail in the literature [24].
2.3. Hardness
The wear testTest
was performed with a DuCom-made Pin-on-Disc tribometer. The ASTM
The surface
G99 standards ofwere
[33] the composite
used as the specimens waswear
basis for the polished with
test in the emery
presentpaper.
work.The speci-
A disk of
mensdiameter
track were then60 used
mmfor obtaining
made the Brinell’s
with EN-32 hardness
steel was number
used as using a Brinell
a counter-face hardness
for testing the
tester. TheThree
specimen. three specimens
composite were
samples were
tested by tested
varyingbased on ASTM
parameters likeE384
load[31]
andstandards.
sliding speed.
Load was varied from 10 N to 30 N with an increment of 10 N, whereas speed was varied
2.4. Tensile
from 500 rpmTest
to 700 rpm with an increment of 100 rpm. The specific wear rate (SWR) was
calculated by using Equation
The tensile strength (1).HMMC specimens was tested using a computer-operated
of the
universal tensile machine, (UTM) INSTRON-3369, with a capacity of 50 kN. A crosshead
∆W
speed of 0.5 mm/min at room temperatureSWR = was applied to the composite specimens. The (1)
ρ × Fn × Sd
tensile test on the composite specimens was conducted as per ASTM E8 [32] standards.
where ∆W is the weight loss, ρ is the density of the specimen, Fn is the normal load and Sd
2.5.
is theWear Testdistance.
sliding
The procedure for the wear test has been explained in detail in the literature [24]. The
wear test was performed with a DuCom-made Pin-on-Disc tribometer. The ASTM G99
standards [33] were used as the basis for the wear test in the present work. A disk of track
diameter 60 mm made with EN-32 steel was used as a counter-face for testing the speci-
men. Three specimens were tested by varying parameters like load and sliding speed.
Load was varied from 10 N to 30 N with an increment of 10 N, whereas speed was varied
from 500 rpm to 700 rpm with an increment of 100 rpm. The specific wear rate (SWR) was
J. Compos. Sci. 2022, 6, x FOR PEER REVIEW 5 of 13

J. Compos. Sci. 2022, 6, 86 where ∆𝑊 is the weight loss, ρ is the density of the specimen, Fn is the normal load
5 of 13
and
Sd is the sliding distance.

3.3. Results
Results and
and Discussion
Discussion
Thetensile
The tensiletest,
test,hardness
hardness test
test and
and the
the wear
wear test results are precisely explained below.
below.
The impact of wear test parameters like
The impact of wear test parameters like applied load,applied load, sliding
sliding speed
speed and
andreinforcement
reinforcement
content on the
content thefriction
frictionbehavior
behaviorofof HMMC
HMMC waswas
studied. Meanwhile,
studied. as theas
Meanwhile, study
the is related
study is
to tribology,
related the specific
to tribology, wear wear
the specific rate and
rate coefficient of friction
and coefficient were
of friction taken
were as structure
taken re-
as structure
sponses. Accordingly,
responses. Accordingly,the theeffect
effectof
of the
the tribo-testing
tribo-testing conditions on the friction
friction behavior
behaviorof of
Al5059/B
Al 5059/B44C/Al
C/Al2O O3
2 3 is studied.
is studied.

3.1.
3.1. Brinell
Brinell Hardness
HardnessTest
TestResults
Results
Brinell’s
Brinell’s hardness
hardness testtest was
was performed
performed on on three
three HMMC
HMMC specimens
specimens and and the
the tested
tested
samples are shown in Figure 2. The mean of the hardness value of the
samples are shown in Figure 2. The mean of the hardness value of the tested specimens is tested specimens
isshown
shown in in Figure
Figure 3. From
3. From the results
the results shown
shown in theinFigure
the Figure
3, the 3, the hardness
hardness value wasvalue was
greater
greater for the sample SP3, which had a higher
for the sample SP3, which had a higher content of B4C and Al content of B C and Al O
4 2O3. The 2tough 3 . The tough
interfacial
interfacial
bond between bond between
the metalthe metal material
matrix matrix material (Al-5059)
(Al-5059) and the andceramic
the ceramic particles
particles (B4C(Band
4C
and Al O
Al2O3)2was ) was the cause for the high hardness value of the specimen, SP3.
3 the cause for the high hardness value of the specimen, SP3. Additionally, the Additionally,
the ceramic particle,
ceramic particle, Al2Al
O32,Owas
3 , was
thethe hardest
hardest material.
material. This
This property
property of of
AlAl O3 could
2O23 could bebe one
one of
of the main reasons for the increase in the hardness of the composite
the main reasons for the increase in the hardness of the composite sample SP3. sample SP3.

J. Compos. Sci. 2022, 6, x FOR PEER REVIEW 6 of 13

Figure2.2.Hybrid
Figure Hybridcomposite
compositespecimens
specimensafter
afterhardness
hardnesstest.
test.

From the literature, it was clearly observed that the increase in the ceramic content in
the composite specimen increased the hardness of the composite specimen [13,14,24].
Bonding between the ceramic and matrix improved the mechanical properties. Similar
results have been observed in the literature and the inference drawn from SEM images
(see Section 4.1) is also in line with the hardness results. The inclusion of ceramic particles
into the matrix material improved the strength; likewise, the ductility of the composite
material decreased and the composite became brittle. From the physics point of view, the
hardness of the brittle material was higher than the ductile material, since the deformation
of the material is less in the brittle material. The presence of B4C and Al2O3 in the interac-
tion makeup up of particles and decreased vacancy content are the reasons for the in-
creased hardness [13]. When the load is applied, reinforcement stops the movement of
dislocations, resulting in an increased hardness. Furthermore, when the wt% of B4C and
Al2O3 reaches its maximum, there is a risk of B4C and Al2O3 particle agglomeration, which
lowers the interfacial adhesion across reinforcement and metal matrix, lowering the com-
posites’ surface hardness.
Figure3.3.Brinell
Figure Brinellhardness
hardnessnumber
number(BHN)
(BHN)for
fortested
testedcomposite
compositespecimens.
specimens.

From the
3.2. Tensile Testliterature,
Results it was clearly observed that the increase in the ceramic content
in theThe
composite specimen
tensile test increased
was carried thethe
out on hardness of the composite
three fabricated specimen
specimens. [13,14,24].
The results of the
Bonding between the ceramic and matrix improved the mechanical properties.
tensile test are shown in Figure 4, from which it is evident that the tensile strength Similar
was
results
higherhave been
in SP3, observed
which had in the literature
a higher and the
percentage of inference drawn from
ceramic particles. TheSEM
wt.%images (see
of ceramic
Section 4.1)
particles inisthis
also in line with
specimen wasthe hardness
7.5% results. The
each. Compared to inclusion of ceramic
the other two particles
specimens, into
the pres-
the matrix material improved the strength; likewise, the ductility of the composite
ence of both Al2O3and B4Cwas high in SP3. Additionally, the level of packing of the ce- material
ramic particles with the matrix material helped add more strength to SP3. The tensile
strength of SP3 was 154 N/mm2, which was more than that of the remaining two speci-
mens. The increase in the ceramic content in the composite material increased the strength
and decreased the elongation percentage. Similar results have been observed in the liter-
J. Compos. Sci. 2022, 6, 86 6 of 13

decreased and the composite became brittle. From the physics point of view, the hardness
of the brittle material was higher than the ductile material, since the deformation of the
material is less in the brittle material. The presence of B4 C and Al2 O3 in the interaction
makeup up of particles and decreased vacancy content are the reasons for the increased
hardness [13]. When the load is applied, reinforcement stops the movement of dislocations,
resulting in an increased hardness. Furthermore, when the wt% of B4 C and Al2 O3 reaches
its maximum, there is a risk of B4 C and Al2 O3 particle agglomeration, which lowers
the interfacial adhesion across reinforcement and metal matrix, lowering the composites’
Figure 3. Brinell hardness number (BHN) for tested composite specimens.
surface hardness.
3.2.
3.2. Tensile Test Results
Tensile Test Results
The
The tensile
tensile test
test was
was carried
carried out
out on the three
on the three fabricated
fabricated specimens.
specimens. The The results
results of
of the
the
tensile
tensile test are shown in Figure 4, from which it is evident that the tensile strength was
test are shown in Figure 4, from which it is evident that the tensile strength was
higher
higher in SP3, which
in SP3, which hadhad aa higher
higher percentage
percentage of of ceramic
ceramic particles.
particles. TheThe wt.%
wt.% of of ceramic
ceramic
particles
particles in this specimen was 7.5% each. Compared to the other two specimens,pres-
in this specimen was 7.5% each. Compared to the other two specimens, the the
ence of both
presence Al2OAl
of both 3and B4Cwas high in SP3. Additionally, the level of packing of the ce-
2 O3 and B4 Cwas high in SP3. Additionally, the level of packing of the
ramic
ceramic particles
particles with
withthethematrix
matrixmaterial
materialhelped
helpedadd addmore
morestrength
strength to to SP3.
SP3. The tensile
The tensile
strength of SP3 was 154 N/mm 2 2, which was more than that of the remaining two speci-
strength of SP3 was 154 N/mm , which was more than that of the remaining two specimens.
mens. The increase
The increase in the in the ceramic
ceramic content content
in thein the composite
composite material
material increased
increased the strength
the strength and
and decreased
decreased the elongation
the elongation percentage.
percentage. Similar
Similar results
results havehave
beenbeen observed
observed in theinliterature,
the liter-
ature, where
where a decrease
a decrease in the elongation
in the elongation percentage
percentage with an with an increase
increase in the composition
in the composition of the
of
ceramic particles has been observed. There was an increase in the strength ofstrength
the ceramic particles has been observed. There was an increase in the of the
the composite
composite
specimen with specimen with aninincrease
an increase the wt.% inof
thethe
wt.% of theparticles.
ceramic ceramic particles.
The mostThe most
likely likely
cause of
cause of this in
this increase increase
tensile in tensileisstrength
strength is hard which
hard particles, particles,
can which can withstand
withstand a greater loada greater
when
load when distributed
uniformly uniformly distributed
in the matrix in phase.
the matrix
Thephase.
applied Theload applied loadtoisthe
is passed passed to the
implanted
implanted
hard particle,hard particle, the
increasing increasing
loadingthe loading
capacity of capacity
the producedof thecomposite.
produced composite.
An increaseAn of
increase
12% and of 12%of
23.2% and 23.2%
tensile of tensile
strength hasstrength has been
been observed withobserved with in
the increase theceramic
increase in ce-
particle
ramic
contentparticle
of 10 wt.%contentandof15 10wt.%,
wt.% respectively,
and 15 wt.%,whereasrespectively, whereas
a decrease a decrease
of 25% of 25%
and 37.5% of
elongation
and 37.5% of in elongation
the composite sample
in the compositewith the increase
sample within theceramic
increasecontent to 10 content
in ceramic wt.% and to
15
10 wt.%,
wt.% andrespectively,
15 wt.%, was observedwas
respectively, in the presentin
observed study.
the present study.

Figure
Figure 4.
4. Tensile strength of
Tensile strength of the
the tested
tested specimen.
specimen.

4. Discussion
4.1. SEM of Fractured Specimens
SEM was used to identify the interfacial bonding and fracture behaviour of the com-
posite specimens. In the present work, the three fractured specimens were investigated
using SEM. The images obtained using SEM are shown in Figure 5. The graph of SP1,
Figure 5a, which has lesser reinforcement content than the other composites, exhibited
voids and ridges with closely spaced ceramic particles. The insufficient distribution of the

J. Compos. Sci. 2022, 6, 86
4. Discussion
4.1. SEM of Fractured Specimens
SEM was used to identify the interfacial bonding and fracture behaviour of the com-
posite specimens. In the present work, the three fractured specimens were investigated
using SEM. The images obtained using SEM are shown in Figure 5. The graph of 7SP1, of 13

Figure 5a, which has lesser reinforcement content than the other composites, exhibited
voids and ridges with closely spaced ceramic particles. The insufficient distribution of the
particles in
particles in aa particular
particular region
region resulted
resulted inin the
the formation
formation of of voids.
voids. Figure
Figure 5b5b of
of specimen
specimen
SP2shows
SP2 showsthe theformation
formation of ofgood
goodbonding.
bonding. This
Thisindicates
indicatesthat
thatananincreased
increasedwt% wt%ofofceramic
ceramic
particles to
particles to the
the metal
metal matrix
matrix restricted
restricted the
the deformation
deformation of of the
the matrix.
matrix. The The improvement
improvement
in the
in the bonding
bonding between
between thethe metal
metal matrix
matrix materials
materials with
with the
the reinforced
reinforced ceramic
ceramic particles
particles
improved the strength of the composites. From these images, it
improved the strength of the composites. From these images, it is also observed thatis also observed that the
the
composite specimen,
composite specimen, SP3, exhibits more bonding of ceramic particles. Thus, Figure
more bonding of ceramic particles. Thus, Figure 5a in- 5a indi-
cates the
dicates poor
the poor bonding
bondingnature
natureof the composite
of the compositesamples
sampleswhich havehave
which a smaller percentage
a smaller percent- of
ceramic
age particles.
of ceramic By contrast,
particles. in Figure
By contrast, in 5b,c there
Figure is there
5b,c an increased wt% of ceramic
is an increased wt% of particles,
ceramic
as evidenced
particles, by the good
as evidenced by thebonding between between
good bonding the ceramic
the particles and the matrix
ceramic particles and thematerial.
matrix
The formation of a particle cluster can be observed in Figure 5a, which
material. The formation of a particle cluster can be observed in Figure 5a, which is quite is quite common in
the MMCs due to improper bonding with the reinforcements, which
common in the MMCs due to improper bonding with the reinforcements, which will lead will lead to the failure
ofthe
to the failure
samples.of the samples.

(a) (b)

(c)
Figure
Figure5.
5.SEM
SEMimages
imagesof
of(a)
(a)SP1,
SP1,(b)
(b)SP2
SP2and
and(c)
(c)SP3.
SP3.

4.2. Effect
4.2. EffectofofLoad
Loadon onSpecific
Specific Wear
Wear Rate
Rate (SWR)
(SWR)
From the
From the literature,
literature, itit was
was evident
evident that
that the
the fabrication
fabrication of
of the
the composites
composites affects
affects the
the
tribological properties [24]. The factors that affect the wear of the fabricated
tribological properties [24]. The factors that affect the wear of the fabricated composite composite
specimens were
specimens were mainly
mainly the
the load
load imparted
impartedon onthe
thespecimen
specimenand
andthe thesize
sizeand
andthe volume
the volume of
the reinforcement particles [14]. The specific wear rate with respect to the
of the reinforcement particles [14]. The specific wear rate with respect to the load impartedload imparted on
the specimen and the corresponding graphs are shown in Figure 6. It is evident from the
on the specimen and the corresponding graphs are shown in Figure 6 It is evident from
graphs that there was an increase in the SWR with the increase in the proportions of the
ceramic particles. A reduction in the SWR corresponding to the increase in the load was also
observed. SP3, which had a higher wt% of both B4 C and Al2 O3 , had a high SWR. Similar
results have been experienced in the literature as well [13]. The ceramic material, B4 C,
being the hardest material, increased the wear rate of the composites. Thus, the increase in
B4 C in the composition reduces the destruction of the fabricated composite and improves
wear resistance, thereby decreasing the specific wear resistance. The reduction of wear loss
of the composites can be associated with an improvement in hardness of manufactured
 Similar results have been experienced in the literature as well [13]. The ceramic material,
B4C, being the hardest material, increased the wear rate of the composites. Thus, the in-
crease in B4C in the composition reduces the destruction of the fabricated composite and
improves wear resistance, thereby decreasing the specific wear resistance. The reduction
J. Compos. Sci. 2022, 6, 86
of wear loss of the composites can be associated with an improvement in hardness 8 of 13
of
manufactured composites by means of the introduction of a harder phase. The wear re-
sistance was less at maximum load condition for SP1, which had a smaller percentage of
reinforcement. This shows
composites by means that when of
of the introduction thea harder
slidingphase.
speedThe is changed at a specific
wear resistance was less load,
at the
wear rate increases. When compared to hardness, it was shown
maximum load condition for SP1, which had a smaller percentage of reinforcement. This that wear loss follows a
similar pattern.
shows that whenAnother conclusion
the sliding is that when
speed is changed a larger
at a specific load,sliding
the wear speed
rate is enforced, the
increases.
Whenloss
wear compared
becomes to hardness, it was shown
more pronounced. that wear loss
According follows
to the a similar
findings, thepattern.
quantity Another
of wear loss
conclusion is that when a larger sliding speed is enforced,
is determined by the applied speed. Abrasive wear was evident from the SEM the wear loss becomes moreimages
pronounced. According to the findings, the quantity of wear loss
(Section 4.5). The SWR is increased as the percentage of the reinforcement particles is determined by the in-
applied speed. Abrasive wear was evident from the SEM images (Section 4.5). The SWR
creased in the composite samples. The increased wear loss at 30 N normal load could be
is increased as the percentage of the reinforcement particles increased in the composite
due to a physical process in which shear forces increase significantly, causing more inter-
samples. The increased wear loss at 30 N normal load could be due to a physical process
face material
in which shearto be lost.increase
forces Elkady significantly,
et al. [34] tested the wear
causing moreactivity
interfaceofmaterial
Cu-based to boron
be lost.nitride
composite materials
Elkady et al. that
[34] tested theused
wearaactivity
slidingofspeed
Cu-basedof 0.2 m/s nitride
boron and varied typical
composite loading. The
materials
findings
that usedrevealed
a slidingaspeed
progressive
of 0.2 m/s riseand
in varied
wear loss, which
typical wasThe
loading. consistent
findingswith typical
revealed a load
fluctuation.
progressive rise in wear loss, which was consistent with typical load fluctuation.

(a) (b)

(c)
Figure
Figure6.6.Influence ofload
Influence of loadon
onSWR
SWRat at a speed
a speed of 500
of (a) (a) 500
rpm,rpm, (b)rpm
(b) 600 600and
rpm(c)and
700(c) 700 rpm.
rpm.

4.3. Impact of Load on the Coefficient of Friction (CoF)

4.3. Impact of Load on the Coefficient of Friction (CoF)
A pin on disk machine attached with the computer was used to display the data
A pin on disk machine attached with the computer was used to display the data gath-
gathered from the tribometer equipped with frictional sensor. Figure 7 exhibits the dissimil-
ered from
itude the
of the tribometer
coefficient equipped
of friction with
(CoF) withfrictional
the load.sensor. Figure
With the 7 exhibits
increase the the
in the load, dissimili-
tude of the coefficient of friction (CoF) with the load. With the increase in the
CoF decreases for all the three composite samples. Additionally, with the increase in the load, the
CoF decreases content
reinforcement for all the
therethree
was composite samples.
decrease in the Additionally,
CoF. This was evident with
from the previous
increase in the
studies also. The integration of hard particles and the good bonding ability at the surface of
the matrix element with the tough particles could involve greater hardness characteristics
and good fracture toughness of the composites, which might also promote a decrease in
the friction coefficient. The increment in the wt% of this ceramic particle increases the
hardness of the composite. The increase in the surface hardness of the composite decreases
the CoF. Besides the enhancement of the reinforcement, the particle content decreases the
 of the matrix element with the tough particles could involve greater hardness charact
istics and good fracture toughness of the composites, which might also promote a decre
in the friction coefficient. The increment in the wt% of this ceramic particle increases
hardness of the composite. The increase in the surface hardness of the composite decrea
J. Compos. Sci. 2022, 6, 86 the CoF. Besides the enhancement of the reinforcement, the particle content9 ofdecreases 13
contact area of the disk as the pin slides against it. This results in the destruction of
disc material as it is exposed to the harder material with higher loads. Hence the C
contact area
reduces. of the diskSnBr
CaO-filled as thealloy
pin slides against it. were
composites This results in the destruction
developed by Gangwar of theetdisc
al. [35]. T
material as it is exposed to the harder material with higher loads.
authors also simulated the wear performance in a dry environment and discoveredHence the CoF reduces.
CaO-filled SnBr alloy composites were developed by Gangwar et al. [35]. The authors
very same phenomenon as in the current investigation. The thin coating can be remov
also simulated the wear performance in a dry environment and discovered the very same
with just a little
phenomenon as inmore exertion
the current in a dry The
investigation. sliding
thin state
coating[36]. Asremoved
can be a result,with
when
just the
a coun
surface makes
little more contact
exertion with
in a dry the pin,
sliding state this
[36]. becomes
As a result,smooth,
when theresulting in greater
counter surface makesfriction
efficients.
contact with the pin, this becomes smooth, resulting in greater friction coefficients.

(a) (b)

(c)
Figure
Figure7.
7. Influence
Influence ofofload
load
onon
CoFCoF
at aat a speed
speed of (a)of
500(a) 500(b)
rpm, rpm, (b) 600
600 rpm and rpm and
(c) 700 (c) 700 rpm.
rpm.

4.4. Optical Microscope

4.4. Optical Microscope
Figure 8 shows the optical microscope image of the three fabricated composite samples.
The Figure 8 shows
white regions which theareoptical
visible microscope image
in the images are of the matrix,
aluminium three fabricated
whereas thecomposite
black sa
ples. Theare
regions white regions which
the micro-pores presentarein visible in the samples.
the composite images are
The aluminium matrix,
porosity is very low wher
in the
the SP3regions
black sample as it can
are thebe observed in Figure
micro-pores present8c.in
Many
the pores are observed
composite samples.in the SP1porosity
The
sample when compared to the SP3 and SP2 samples. Proposer stirring is one of the major
very low in the SP3 sample as it can be observed in Figure 8c. Many pores are observed
causes for the porosity reduction in the composite samples. During the solidification of the
the SP1 sample when compared to the SP3 and SP2 samples. Proposer stirring is one
composite samples, porosities are removed much as the molten metal falls from top to the
the major
bottom in causes
the die, for
whichtheremoves
porosity allreduction inthat
the gases so thethe
composite
pores are samples.
eliminatedDuring the solid
[37]. The
cation ofobtained
porosity the composite samples,
in the optical porosities
microscopy imagesare removed
correlates wellmuch asmicrostructure.
with the the molten metal fa
from top to the bottom in the die, which removes all the gases so that the pores are elim
nated [37]. The porosity obtained in the optical microscopy images correlates well w
the microstructure.
J.J.Compos.
Compos.Sci. 2022,6,6,86
Sci.2022, x FOR PEER REVIEW 10 of
10 of 13
13

Figure8.8.Optical
Figure Opticalmicrostructures
microstructuresofof(a)
(a)SP1,
SP1,(b)
(b)SP2
SP2and
and(c)
(c)SP3.
SP3.

4.5.
4.5.SEM
SEMofofthetheWear-Tested
Wear-TestedSpecimens
Specimens
The
Thecharacterization
characterizationofofthe thesamples
sampleswas wasinvestigated
investigatedusing usingSEM.
SEM.TheThebasic
basicaimaimofofthe
the
microstructure
microstructurestudy studyon onthe
thewear-tested
wear-testedsamples
samplesisisto toknow
knowthe thenature
natureof of the
the wear
wear tracks.
tracks.
The
Theimages
imagesfromfromSEM SEM areare
shown
shown in Figure 9. From
in Figure 9. From the the
figures, the wear
figures, type type
the wear observed was
observed
abrasive wear. The increase in the weight percentage of the ceramic
was abrasive wear. The increase in the weight percentage of the ceramic particles resulted particles resulted in an
increase in the wear resistance of the specimen. This is depicted in
in an increase in the wear resistance of the specimen. This is depicted in Figure 8a–c. The Figure 8a–c. The SEM
micrographs
SEM micrographs of all theofthree fabricated
all the three composite
fabricated samples
composite exhibit longitudinal
samples exhibitgrooves with
longitudinal
some minute partial irregular pits; this indicates an adhesive type
grooves with some minute partial irregular pits; this indicates an adhesive type of wearof wear in the composite
samples. The presence
in the composite samples.of grooves in the wear-tested
The presence of grooves composite samples composite
in the wear-tested indicates the effect
samples
of
indicates the effect of micro cutting and micro ploughing on the counter-face, whereasare
micro cutting and micro ploughing on the counter-face, whereas the depths or prows the
symbolic
depths orofprows
adhesiveare failure
symbolic of the Al 5059/B
of adhesive 4 C/Alof
failure 2 Othe
3 hybrid composite
Al 5059/B [38]. Figure 9c of
4C/Al2O3 hybrid compo-
SP3,
site which had a 9c
[38]. Figure highof content
SP3, whichof B4had
C and Al2 Ocontent
a high 3 , shows ofaBreduction in wedges and grooves
4C and Al2O3, shows a reduction
as compared to Figure 9a, which had a high number
in wedges and grooves as compared to Figure 9a, which had a high of wedges and grooves.
number The
of surface
wedges
microscopy following the loading condition displayed particular cracks coupled with
and grooves. The surface microscopy following the loading condition displayed particular
continuous grooves when the quantity of reinforcements was increased. The continuous
cracks coupled with continuous grooves when the quantity of reinforcements was in-
ridges are most likely the source of the asperities’ strong absorption. The abrasion activity
creased. The continuous ridges are most likely the source of the asperities’ strong absorp-
in connection to fractured hard reinforcement particles which serve as third layer abrasions
tion. The abrasion activity in connection to fractured hard reinforcement particles which
could promote action. The surface of a unique composite containing higher reinforcement
serve as third layer abrasions could promote action. The surface of a unique composite
content shows the production of a complicated wear process that involves macro fractures
containing higher reinforcement content shows the production of a complicated wear pro-
and debonding wear patterns, and even some segregation particles. A specimen with a
cess that involves macro fractures and debonding wear patterns, and even some segrega-
lesser amount of reinforcement particles exhibited less wear resistance. Figure 9b exhibits a
tion particles. A specimen with a lesser amount of reinforcement particles exhibited less
wedge line along with clusters and voids. This shows a lesser wear resistance compared
wear resistance. Figure 9b exhibits a wedge line along with clusters and voids. This shows
to SP3. More wear resistance was observed in SP3 when compared to SP2. Ceramic
a lesser wear
particles resistance
restricted compared
the wear behaviorto SP3. More
of the wear resistance
composite samples; was theobserved
higher thein SP3 when
number
compared
of ceramic to SP2. Ceramic
particles, particles
the higher the restricted the wearsince
wear resistance, behavior of the composite
the ceramic particlessamples;
restrict
the higher the number of ceramic particles, the higher
the composite sample from deformation, which increase the sample’s hardness. the wear resistance, since theHardce-
ramic particles restrict the composite sample from deformation,
material is prone to wear resistance. The lower wear loss is due to a higher reinforcementwhich increase the sam-
ple’scontent,
wt% hardness. Hardprovides
which material aisstronger
prone toadhering
wear resistance.
mechanism The lower
betweenwear loss
the is due
base to a
matrix
higher reinforcement wt% content, which provides a stronger
and the hard reinforcement particles. As a result, this composition has better hardness adhering mechanism be-
tween the base matrix and the hard reinforcement particles. As a result, this composition
J.J.Compos.
Compos.Sci.
Sci.2022,
2022,6,6,x86
FOR PEER REVIEW 1111ofof13
13

characteristics.
has Thecharacteristics.
better hardness utilization of composite materials
The utilization has increased
of composite recently
materials has due to the
increased
higher wear
recently resistance
due to especially
the higher in the tribological
wear resistance especiallyapplications.
in the tribological applications.

(a) (b)

(c)
Figure
Figure9.9.SEM
SEMimages
imagesof
ofwear
wearsamples
samples(a)
(a)SP1,
SP1,(b)
(b)SP2
SP2and
and(c)
(c)SP3.
SP3.

5.5.Conclusions
Conclusions
Inthe
In the present
present study,
study, aa matrix
matrix material,
material,AlAl5059,
5059,was
wasmixed
mixedwith
withequal
equalproportions
proportionsof
ceramic materials, B C and
of ceramic materials,4 B4C and AlAl O . The wt% of the combined ceramic materials considered
2 23O3. The wt% of the combined ceramic materials consid-
was 5%,
ered was10%
5%, and
10%15%.
and Using the stirthe
15%. Using casting method,method,
stir casting three specimens were fabricated.
three specimens The
were fabri-
testedThe
cated. specimens of HMMCofexhibited
tested specimens improvement
HMMC exhibited in the mechanical
improvement properties
in the mechanical of the
proper-
metal matrix with an increase in the reinforcement content. The following observations
ties of the metal matrix with an increase in the reinforcement content. The following ob-
were drawn
servations from
were the wear
drawn fromtest
theand
wear SEM
testanalysis.
and SEM analysis.
1.1. Thereisisan
There anincrease
increaseininthe
thewear
wearresistance
resistanceofofthe
theHMMC
HMMCspecimens
specimenswith withan anincrease
increase
in the wt% of ceramic particles.
in the wt% of ceramic particles.
2.2. TheSWR
The SWRofofthe
thefabricated
fabricatedspecimens
specimensdecreased
decreasedwithwithananincrease
increaseininthetheload
loadon onthe
the
specimens.The TheSWRSWRofofSP3SP3atat3030NNload
loadwaswasobserved
observedtotobe be6565×× 6 3
specimens. 1010
6 mm mm3/Nm./Nm.
3.3. The CoF decreases with an increase in the wt% percentage of the ceramic
The CoF decreases with an increase in the wt% percentage of the ceramic particles in particles in
the fabricated specimens. The increase in the load also leads to a decrease
the fabricated specimens. The increase in the load also leads to a decrease in the CoF in the CoF
ofofthe
theHMMC
HMMCspecimens.
specimens.The TheCoFCoFofof SP3
SP3 was
was observed
observed toto
bebe 0.27
0.27 at at
3030NNloadload and
and a
a speed of 700
speed of 700 rpm. rpm.
4.4. AAconsistency
consistencyininthe
thedistribution
distributionofofthe
theceramic
ceramicparticles
particleshas
hasbeen
beenidentified
identifiedfromfromthe
the
SEM images of the fractured specimens under tensile
SEM images of the fractured specimens under tensile testing. testing.
5.5. AAvirtual
virtualdecrease
decreaseininthetheexistence
existenceofofvoids
voidsand
andgrooves
grooveshashasbeen
beendetermined
determinedfrom from
the SEM images.
the SEM images.

Author Contributions: Conceptualization, P.V.R. and S.V.; methodology, U.P.; formal analysis,
P.V.R. and U.P.; investigation, P.V.R.; resources, U.P., S.V. and M.C.; data curation, U.P. and M.C.;
J. Compos. Sci. 2022, 6, 86 12 of 13

Author Contributions: Conceptualization, P.V.R. and S.V.; methodology, U.P.; formal analysis, P.V.R.
and U.P.; investigation, P.V.R.; resources, U.P., S.V. and M.C.; data curation, U.P. and M.C.; writing—
original draft preparation, U.P.; writing—review and editing, P.V.R. and S.V.; visualization, M.C.;
supervision, P.V.R. All authors have read and agreed to the published version of the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The related data as discussed in this article can be requested from the
corresponding author P.V.R. or M.C.
Conflicts of Interest: The authors declare no conflict of interest.

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