Statistical Analysis of Dry Sliding Wear Process Parameters for AZ91 Alloy Processed by RD-ECAP Using Response Surface Methodology

Bassiouny Saleh,Jinghua Jiang,Qiong Xu,Reham Fathi,Aibin Ma,Yuhua Li,Lisha Wang 대한금속·재료학회 2021 METALS AND MATERIALS International Vol.27 No.8

The main objective of this paper is to study the influence of wear testing parameters on the weight loss of AZ91 magnesiumalloy which was developed via rotary die-equal channel angular pressing (RD-ECAP) method through the different numberof passes. The AZ91 sample was pressed up to 16 passes in order to decrease the grain size to 10 μm. After RD-ECAP processing,significant grain refinement was found, which yielded a refined grain size after 16 passes and enhanced mechanicalproperties and wear resistance. Dry sliding wear experiments with a ball on disc apparatus at room temperature were conducted,following RD-ECAP processing. The response surface methodology (RSM) was used to optimize and compare thewear resistance of the RD-ECAP alloy and the as-received alloy. Analysis of the wear mechanism and the worn surfaces ofAZ91 samples was performed using scanning electron microscope. RSM analysis showed that increased applied load, slidingspeed and sliding time in all cases decreased wear resistance. On the other side, wear resistance in AZ91 magnesium alloywas improved by the increase in the number of passes of RD-ECAP. The three empirical models were validated by conductingconfirmation tests and certified that the proven empirical wear models are reliable for wear applications as a predictive tool.

Review on the Influence of Different Reinforcements on the Microstructure and Wear Behavior of Functionally Graded Aluminum Matrix Composites by Centrifugal Casting

Bassiouny Saleh,Jinghua Jiang,Aibin Ma,Dan Song,Donghui Yang,Qiong Xu 대한금속·재료학회 2020 METALS AND MATERIALS International Vol.26 No.7

The main objective of the present paper is to draw the attention of researchers towards the wear analysis of functionallygraded aluminum matrix composites (FGAMCs) reinforced with different types of particles. The quality of the productsand characteristics achieved by the functionally graded materials (FGMs) has been given increasing attention during recentdecades. FGMs provide a way to obtain gradients between two phases with variations of properties. The centrifuge castingprocess was used to produce continuous variation of graded materials. These continuous graded materials offer high strengthand enhanced wear resistances compared with traditional composite materials. This paper summarizes the effect of the variousreinforcement materials and wear test parameters on microstructure as well as wear properties in the FGAMCs obtainedthrough the centrifugal casting technique. The results found in the reviewed literature are classified according to types ofreinforcement particles (such as silicon carbide, alumina and boron carbide) and the influence of wear test parameters (suchas applied load, sliding distance, duration and sliding speed) on FGM composites. The main conclusions in this paper arederived from previous studies on experimental investigations on the wear characteristics of FGAMCs. The research gapsand future directions have been discussed which will be prolific to the researchers in the design and manufacture of FGMsproduction by centrifugal casting.

Development of Functionally Graded Tubes Based on Pure Al/Al2O3 Metal Matrix Composites Manufactured by Centrifugal Casting for Automotive Applications

Bassiouny I. Saleh,Mahmoud H. Ahmed 대한금속·재료학회 2020 METALS AND MATERIALS International Vol.26 No.9

This paper studies the influence of main parameters on the mechanical properties and wear behaviour of functionallygraded materials pure Aluminum reinforced by various weight fractions of aluminium oxide (Al2O3). A Functionallygraded (FG) pure aluminium/Al2O3 tube was processed by horizontal centrifugal casting method. The hollow tube dimensionsare 230 mm outer diameter x 12 mm thickness x 180 mm length. The properties of these FG tubes were comparedwith unreinforced alloy. Hardness and tensile results in the radial direction showed that the hardness and tensile inaccordance with the gradient microstructure was improved from inner zone to outer zone. Wear tests were carried out fordifferent test duration at a constant sliding speed of 8 m/s and loads applied are 14, 24 and 40 N. In all test conditions thewear rate in the outer layer was minimum compared to other layers. In the surface analysis, scanning electron microscopeindicated the presence of delamination, wear debris and cracks. FG tubes reinforced by Al2O3particles have increasedmechanical properties and wear resistance compared to its unreinforced alloy (matrix alloy) and is suitable for use inautomobile and transport applications.

Effect of Main Parameters on the Mechanical and Wear Behaviour of Functionally Graded Materials by Centrifugal Casting: A Review

Bassiouny Saleh,Jinghua Jiang,Aibin Ma,Dan Song,Donghui Yang 대한금속·재료학회 2019 METALS AND MATERIALS International Vol.25 No.6

Mechanical characteristics of functionally graded materials (FGMs) can be optimized for specific application depending onthe demands of different engineering sectors using appropriate combinations of material amounts and processing parameters. In recent years, many approaches to the production of functionally graded metal matrix composites (FGMMCs) using thecentrifugal casting method have been proposed. This paper presents an overview of different available materials and processparameters for FGMs based on their mechanical and wear characteristics. The major conclusions in this paper are drawnfrom the previous studies on experimental investigations on mechanical properties and wear characteristics of FGMMCs. The findings in current work are classified according to material parameters such as the type of matrix material, reinforcingmaterial (type, weight, and size), in addition to process parameters such as mould rotational speed and pouring temperature.

Optimization of the Experimental Parameters Affecting the Corrosion Behavior for Mg–Y–Zn–Mn Alloy via Response Surface Methodology

Lisha Wang,Jinghua Jiang,Bassiouny Saleh,Reham Fathi,He Huang,Huan Liu,Aibin Ma 대한금속·재료학회 2021 METALS AND MATERIALS International Vol.27 No.12

This paper optimizes experimental parameters on controlling corrosion performance of the Mg-rare-earth alloys with longperiod stacking ordered structure using response surface methodology. Different NaCl concentrations, temperatures, andvarying pH values are selected as input parameters. The corrosion current density (icorr) and open circuit potential (OCP)are used as the multiple responses to evaluate the corrosion performances. The corrosion surface morphology and corrosionmechanism of the Mg alloys are also investigated by scanning electron microscopy for the optimization. Analysis of variance(ANOVA) has given the impact of individual factors and interactions on the corrosion rate. The results indicated thatthe three test parameters had significant impacts in controlling the corrosion behavior of Mg alloy. Moreover, the increasedNaCl concentration decreased the pitting potential (Epit) of the target materials. Filiform corrosion can be detected in high pHsolutions, whereas the matrix suffered from severe dissolution phenomenon in low pH solutions. High temperature aggravatedthe local destruction and dissolution of the protective film. The interaction of the experimental parameters showed a sizableinfluence on corrosion performance.

Duplex and Composite Coatings: A Thematic Review on Thermal Spray Techniques and Applications

M. Sathish,N. Radhika,Bassiouny Saleh 대한금속·재료학회 2023 METALS AND MATERIALS International Vol.29 No.5

Thermal spraying is a broad terminology for a coating process in which materials are deposited in a spray of finely distributedliquefied or semi-liquefied particulates to build layered deposition coatings. Duplex and composite coatings can be utilizedin the thermal spray technique to enhance the tribological properties of a broad range of engineering materials while savingmoney; service life extension, maintenance expenses, and replacement costs are lower than for single-layered coatings. As aresult, this paper critically analyses various pre-processing surface treatments for substrates, commonly used thermal sprayprocessing methods, and various post-processing surface treatments for thermally sprayed substrate materials. This paperalso includes a description of several characterization methodologies as well as some comprehensive prospective applicationsfor engineering components with challenges and scopes. Thus, this paper provides a fundamental understanding of surfacetreatments to researchers who use thermal spray coating techniques.