Dry sliding wear behaviour of friction stir processed (FSP) AZ31 and AZ31/ZrC particles (5, 10, and 15 vol%) reinforced surface composite was investigated at different sliding speeds and loads. The samples were tested using a pin-on-disc apparatus with EN31 steel as the counter body to determine the role of FSP and ZrC reinforcement on the microstructure, hardness, and wear behaviour of AZ31. Base metal AZ31 alloy exhibits a hardness of 60 HV, whereas the 15 vol% ZrC-reinforced composites had the highest hardness of 108 HV. It was also identified that 15 vol% ZrC-reinforced composites exhibited lowest wear rate and friction coefficient under all testing conditions. Abrasion, delamination, oxidation, material softening, and plastic deformation are the primary wear mechanisms viewed from the wear tracks of the samples. Higher volume fraction of ZrC particles exhibited better wear resistance at all speeds and loads than AZ31 alloy. A wear map has been generated for different material compositions and wear conditions to identify the main wear mechanisms easily.

Department of Machining Assembly and Engineering Metrology Faculty of Mechanical Engineering VSB Technical University of Ostrava 70800 Ostrava Czech Republic

Department of Mechanical Engineering Amrita School of Engineering Amrita Vishwa Vidyapeetham Coimbatore India

Department of Mechanical Engineering Karpagam College of Engineering Coimbatore India

Department of Mechanical Engineering Vel Tech Rangarajan Dr Sagunthala R and D Institute of Science and Technology Avadi Chennai 600062 India

Department of Physics PSG Polytechnic College Coimbatore Tamil Nadu India

University Centre for Research and Development Chandigarh University Mohali 140413 India

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