Hibrit mikrodalga ısıtma yöntemiyle üretilen Al5Cu-B4C-Gr hibrit kompozitlerin kuru kayma aşınma davranışı

Abstract

Bu çalışmada, farklı oranlarda bor karbür (B4C) ve grafit (Gr) ile takviye edilmiş Al5Cu matrisli hibrit kompozitler toz metalurjisi yöntemiyle üretilmiş ve ardından hibrit mikrodalga sinterleme uygulanmıştır. B4C ve Gr içeriklerinin kompozitlerin fiziksel, mikroyapısal, mekanik ve kuru kayma aşınma davranışları üzerindeki etkileri sistematik olarak incelenmiştir. Toz karakterizasyonu, düzensiz şekilli Al, küresele yakın Cu, köşeli B4C ve lamelli Gr partiküllerinin yoğunlaşma davranışı ve takviye dağılımı üzerinde etkili olan heterojen bir başlangıç toz mimarisi oluşturduğunu göstermiştir. Sinterleme sonrasında tüm numunelerde bağıl yoğunluk artmış ve porozite azalmıştır. En yüksek sinterlenmiş yoğunluk ve sinterlenebilirlik değeri (%37,26), en düşük toplam takviye oranına sahip AC1 numunesinde elde edilmiştir. XRD analizi Al matrisi, B4C, Gr, Al2Cu, Al2O3 ve Al7Cu2Fe fazlarının varlığını doğrulamıştır. SEM-EDX sonuçları, B4C ve Gr fazlarının matris içinde korunduğunu ve Al7Cu2Fe-tipi faz oluşumuyla ilişkili yerel Al–Fe–Cu zenginleşmesini desteklemiştir. En yüksek Brinell sertliği (65,23 HB) ve mikrosertlik (88,30 HV0,05) değerleri, yüksek B4C içeriği ve yeterli yoğunlaşma nedeniyle AC2 numunesinde gözlenmiştir. Buna karşılık, en düşük ortalama sürtünme katsayısı AC3 numunesinde (0,5040), en düşük özgül aşınma oranı ise AC4 numunesinde (1,9079 × 10-3 mm3/Nm) elde edilmiştir. Sonuçlar, aşınma direncinin yalnızca sertlik tarafından değil; B4C’nin yük taşıyıcı etkisi, Gr’nin yağlayıcı davranışı ve hibrit mikrodalga sinterleme sırasında gelişen mikroyapısal durumun birlikte etkisiyle belirlendiğini göstermektedir.

Keywords

• Alüminyum matris kompozitleri
• Grafit (Gr)
• Hibrit mikrodalga sinterleme
• Kuru kayma aşınması
• Bor karbür

Dry sliding wear behavior of Al5Cu-B4C-Gr hybrid composites fabricated by hybrid microwave heating

Abstract

In this study, Al5Cu matrix hybrid composites reinforced with varying ratios of boron carbide (B4C) and graphite (Gr) were produced via powder metallurgy, followed by hybrid microwave sintering. The effects of B4C and Gr contents on the physical, microstructural, mechanical, and dry sliding wear behavior of the composites were systematically evaluated. Powder characterization revealed that irregular Al, spheroidal Cu, angular B4C, and lamellar Gr particles formed a heterogeneous initial powder architecture that influenced densification and the distribution of reinforcement. After sintering, all samples exhibited increased relative density and reduced porosity. The highest sintered density and sinterability value (37.26%) were obtained for AC1, which had the lowest total reinforcement content. XRD analysis confirmed the presence of the Al matrix, B4C, Gr, Al2Cu, Al2O3, and Al7Cu2Fe phases. SEM-EDX results supported the retention of B4C and Gr within the matrix and confirmed the local Al-Fe-Cu enrichment associated with Al7Cu2Fe-type phase formation. The highest Brinell hardness (65.23 HB) and microhardness (88.30 HV0.05) were observed for AC2, owing to its higher B4C content and sufficient densification. In contrast, the lowest average coefficient of friction was measured for AC3 (0.5040), while the lowest specific wear rate was obtained for AC4 (1.9079×10-3 mm3/Nm). These results show that wear resistance was governed not by hardness alone, but by the combined load-bearing effect of B4C, the lubricating action of Gr, and the microstructural state developed during hybrid microwave sintering.

Keywords

• Aluminum matrix composites
• Graphite (Gr)
• Hybrid microwave sintering
• Dry sliding wear
• Boron carbide

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