Effect of particle size and weight fraction of SiC on the mechanical, tribological, morphological, and structural properties of Al-5.6Zn-2.2Mg-1.3Cu composites using RSM: fabrication, characterization, and modelling

Stir-casting was employed to create Al-5.6Zn-2.2Mg-1.3Cu composites with particle sizes ranging from 30 to 90 μm and a weight fraction of 5–15 SiC articles. The mechanical and wear properties of the material have been assessed. The wear-behaviour of Al-5.6Zn-2.2Mg-1.3Cu composites was investigated using dry pin-on-disc wear testing. Various loads (20 N–60 N), speeds (2 m/s–6 m/s), and sliding-distances were used in the sliding wear experiments (2000 m–4000 m). In the experimental process, XRD, SEM, and EDX were used to characterize the microstructures and materials of diverse composites. Uniform dispersion of the SiC particles is clearly observed in the SEM image. The micro hardness of SiC particles increases by 13% when the weight percent of SiC particles is increased from 5% to 15%. SiC particles outperform tiny SiC particles in terms of wear-resistance. With increasing load, the particular wear-rate showed an increasing trend (20–60 N). The wear-rate of the composite lowers as the weight percentage reinforcement increases (wt. 5% to wt. 15%), and the wear-rate of the composite increases when the particle-size (30 μm–90 μm) increases. The results demonstrated that composites supplemented with coarse SiC particles outperform tiny SiC particles in terms of wear resistance.