Dry and Lubrication Sliding Wear Characteristics and Wear Mechanism Mapping for In Situ Al–25Mg2Si Composites

This study investigates the wear characteristics of Al–25Mg 2 Si composite synthesized via gravity casting. The research aims to understand the influence of applied load, test temperature, contact condition (dry and lubrication), and sliding distance on wear characteristics. Results show that higher loads and temperatures lead to increased wear loss and coefficient of friction. The worn surface morphology for higher loads and temperature shows deeper scratches and grooves, indicating severity in wear. The debris size and volume increase with an increase in load and temperature. The dominant mechanism is abrasive, adhesive, and oxidative for both the room‐ and high‐temperature dry sliding conditions. However adhesive and oxidative wear increase with the increase in test temperature. Abrasive wear is the only wear mechanism present during the lubricating sliding condition. Wear transition is noticed during the wear map analysis subjected to load, temperature, and sliding distance. In the case of room‐temperature test, severe–moderate–mild wear transition occurs with the increase in sliding distance and mild–moderate–severe wear transition occurs with the increase in test temperature and applied load. The roughness of the worn surface increases with an increase in applied load and temperature and the use of lubricant hugely reduces the surface roughness.