Determining the Significance of Cobalt Addition on the Wear Characteristics of Al-6.6Si-0.4Mg Hypoeutectic Alloy Using Design of Experiment

Aluminium alloys have found application in many areas like aerospace industries and automobiles specifically in Machine tool parts, aircraft wheels, pump parts, marine hardware, valve bodies and automotive pistons, owed to their strength to low weight ratio. The present study deals with the growing demand for more durable aluminum alloys for the engine components with improved mechanical property/ tribological properties majorly focusing on the area of wear and tear in engine piston systems. In the present research, the simultaneous effect of cobalt (Co) addition and wear testing factors on the wear resistance of Al-6.6Si-0.4Mg hypoeutectic alloy is investigated through response surface methodology (RSM), a system employed in the design of experiments. Using Minitab software, the regression analysis was done and an equation was formulated to forecast the wear rate and also to investigate the significance of each experimental parameter on the subsequent wear rate. It was found from the current research that, with a surge in the cobalt content, the wear resistance of the alloy increased. It was also noted that, the wear rate was found to increase with an increase in the sliding velocity and load. Whereas, wear rate decreases with an increase in the sliding distance. In order to obtain the minimal wear rate, optimal values for each parameter were found out. FESEM investigation was conducted on the worn-out specimen to evaluate the worn-out surface of the regular and modified alloy for different wear testing conditions.