On the wear behavior of advanced Al matrix composite reinforced with 3D lattice Ni

In the present study, Ni foam-reinforced Al matrix composites were fabricated at three different sintering temperatures: 450°C, 500°C, and 550°C. Microstructural investigations illustrated the formation of the intermetallic phase Al 3 Ni in the interface of Ni foam and Al matrix, with complete Al 3 Ni 2 formation observed at 550°C sintering temperature. The hardness of the system increased with increasing sintering temperature due to the reduction in porosity and the formation of intermetallic compounds. With increasing sintering temperature, the hardness of the Al 3 Ni layer increased to 510 HV, and the hardness of the Al 3 Ni 2 layer increased to 635 HV, due to the increased thickness of these layers. Wear tests were conducted over a distance of 1000 m under a constant linear velocity of 0.3 m/s. Increasing the sintering temperature led to a reduction in friction coefficient and improved wear resistance. This effect can be attributed to the reduction in wear debris and the increase in worn scar volume. The wear mechanism changed from severe adhesive wear to abrasive wear with an increase in sintering temperature, causing craters to form in all samples. The foam struts eventually prevented direct contact and plastic deformation of the sub-surfaces, which in turn transferred normal and shear stresses caused by wear from the matrix to the whole system, leading to an increase in wear resistance.