Role of matrix alloy, reinforcement size and fraction in the sliding wear behaviour of Al-SiCp MMCs against brake pad material

Aluminium metal matrix composites were produced by a newly developed stirring device for stir casting with different matrix alloys, SiC particle fractions and sizes to investigate these parameters' influence on the materials' wear performance. The wear performance of the composites was evaluated with dry sliding pin-on-plate tests against a high-speed train brake pad, and the study of wear surfaces was completed by electron microscopy. The formation of an iron-based tribolayer during wear protected the metal matrix composite from further wear damage. The composite reinforced with 19% SiC particles sized 32 μm showed an increasing coefficient of friction during wear, and the wear surface showed traces of third body wear. The rare earth and transition metal added to the matrix alloy increased the hardness of the composite, and the intermetallic phases reduced the development of the Fe-based tribolayer. The composites with small SiC particles presented the Fe transfer on the exposed aluminium surface, with a lower wear rate and friction coefficient than other composites. The direct comparison of composites produced with different sizes of SiC particles highlighted that the relationship between the wear rate and the coefficient of friction of the composites and the brake pad showed a linear trend.