PSI - Issue 72

Dharmik Chauhan et al. / Procedia Structural Integrity 72 (2025) 529–537

533

A statistical program was used to analyse the experimental data from the wear tests. A model was developed to predict the wear rate based on the considered process parameters. A total of 15 tests were carried out to cover the Box-Behnken design and investigate how the input parameters influence the wear loss of the casted composite, as shown in Table 3. 3. Results In this section, wear test, Vicker Hardness, Optical microstructure and X-ray diffraction result are discussed for the FGAM.

3.1. Wear test

In this study use the pin-on-disc tribometer for the wear test. We calculate the specific wear rate for the pin heating experiment test. Results are given in table 4.

Table 4. Specific wear rate values Sr. No. Normal Load (N)

Sliding Speed (m/s)

Temperature (°C) Distance (m)

WearLoss (mg)

SWR (×10 -6 mm 3 /N·m)

1 2 3 4 5 6 7 8 9

25 40 10 40 10 25 40 25 25 10 25 40 10 25 25

0.50 1.25 2.00 2.00 1.25 0.50 1.25 1.25 1.25 0.50 2.00 0.50 1.25 2.00 1.25

50

4000 640 250 250 640 640 640 640 4000 4000

3.4 0.3 0.4 3.7 0.2 4.5 6.7 7.6 4.4 1.8 3.7 3.5 0.4 0.5 0.4

12.61

200 125 125

4.36

58.83

137.57

50

11.64 16.69 96.74

200

50

125 125 125 125 200 200 125 50

176.52 102.20

10 11 12 13 14 15

16.72

250

219.82

4000

8.13

640 250 640

23.27 30.00

9.29

The Specific Wear Rate (SWR) was calculated for all experimental conditions using the relation:

Wear Volume

SWR=

(1)

NormalLoad× SlidingDistance

where wear volume was obtained by converting the measured wear loss using the composite density of 2.69g/cm 3 . The lowest SWR values indicate excellent wear resistance, which is typically observed under a high normal load of 40 N, a moderate speed of 1.25 m/s, and a relatively low sliding distance of 640-4000 m. This can be attributed to an increased real contact area at higher loads, which leads to a more stable wear interface and reduced material loss. The highest SWR values (219.82 and 176.52) were recorded under combinations of moderate loads (25 N) and short sliding distances (250–640 m). In these cases, even small wear losses result in high SWR values due to the low denominator (product of load and distance). Additionally, higher sliding speeds in some of these trials could increase localized heating, which promotes wear through softening and oxidation mechanisms. Generally, an inverse