Fabrication and characterization of ZrO2 reinforced Fe-20Cr alloy composites

The reinforcement effects of the ZrO 2 and the wear and mechanical behaviour of (Fe,Cr)-based alloy composites were investigated. The (100−x) (Fe80Cr20) -(x) ZrO 2 composites were fabricated via powder metallurgy. The iron-chromium and ZrO 2 powders were efficiently milled and mixed in ball mill. In the Fe80Cr20 alloy, the effect was investigated by changing the ZrO 2 composition by 5%, 10%, and 15%. The blended powder mixture was cold compacted and sintered at 1030 °C. Scanning electron microscopy (SEM), elemental mapping, and x-ray diffraction techniques were utilized to assess the microstructural properties of the sintered composites. In addition, the mechanical properties such as hardness, flexural strength, and porosity were examined with variations in ZrO 2 composites. The dry sliding wear tests with various normal loads and a constant sliding distance were used to find the composite’s wear behaviour. The composite containing 10% ZrO 2 has shown the maximum flexural strength with 1470 MPa, and hardness 359.8 HV 10 respectively, compared to 5% ZrO 2 and 15% ZrO 2 . With a concentration of 10 wt.% ZrO 2 , the wear resistance is found to be significantly enhanced, while after 10 wt.% ZrO 2 , its properties deteriorate. In addition to having improved interfacial bonding, lower porosity, and microstructure uniformity, Fe80Cr20 (Fe-20 Cr) −10 wt% ZrO 2 composites exhibit superior mechanical properties compared to other materials.