Fatigue and Wear Behavior of Al6061–Graphene Composites Synthesized by Powder Metallurgy

Abstract

Graphene being one of the allotropes of carbon, has attracted and evoked keen interest in recent times as an ideal reinforcement for the composites due its outstanding strength. In the current research work, the fatigue and wear behavior of Al6061–Graphene (varying weight fraction 0.2, 0.4, 0.6 wt%) particulate composite are investigated in comparison with monolithic alloy. Initially dispersion of Graphene is carried out by ultra-sonication followed by ball milling on adding Al6061 alloy powder, consolidated by powder metallurgy process and subjected to sintering under inert gas atmosphere. The investigation on the effect of Graphene flakes on micro hardness, mass loss, coefficient of friction and surface roughness values are done under different loading conditions for the prepared samples and wear tracks are analyzed under a microscope. The possible reasons for crack initiation and subsequent fatigue failure under cyclic loading with stress ratio R = −1(sinusoidal waveform), cyclic frequency 5 Hz and stress amplitude 40–140 MPa at room temperature conditions and the type of wear due to increase in Graphene weight fractions were studied through tests results and SEM characterizations.