Metaheuristic Approach to Enhance Wear Characteristics of Novel AA7178/nSiC Metal Matrix Composites

This study aims to enhance understanding of material wear behavior by investigating the microstructure and wear characteristics of AA7178 matrix alloy reinforced with varying wt.% (0, 1, 2, and 3%) of nano-SiC particles, fabricated through stir-casting. The research addresses deficiencies in current materials used in aerospace components, where wear resistance is crucial. These materials often suffer from inadequate wear resistance, surface damage susceptibility, and rapid degradation under abrasive conditions, resulting in increased maintenance costs, reduced component lifespans, and diminished system efficiency. To address these issues, the hypothesis posits that integrating nano-SiC particles into the AA7178 matrix alloy will enhance wear resistance and advance high-performance metal matrix composites. The dry sliding wear behavior of the nanocomposites was examined using a pin-on-disc wear test apparatus with EN31 steel as the counterbody material. Systematic variations in sliding velocity (1, 2, 3, and 4 m/s), distance (500, 1000, 1500, and 2000 m), and load (10, 20, 30, and 40 N) were conducted. Employing the L16 Taguchi method, experimental research and wear analysis revealed that the most influential factor affecting wear rate was the applied load (67.39%), followed by the SiC wt.% (30.85%), with an R2 value of 99.80%. Optimization of wear process parameters was achieved through metaheuristic techniques, encompassing the Rao-1, Particle Swarm Optimization (PSO), and Artificial Bee Colony (ABC) algorithms. The Rao-1 technique demonstrated robustness at approximately 98%, displaying higher efficiency in parameter optimization. Optical microscope analysis identified micro-cutting and micro-ploughing as the primary wear mechanisms. Under specific conditions—9.81 N applied load, 4 m/s sliding speed, 500 m wear distance, and a 3% SiC wt.%—the AA7178/SiC composites exhibited optimal wear resistance, measuring 1.7088*10−3 mm3/m. These findings offer critical guidance for engineering high-performance metal matrix composites, effectively addressing the inherent deficiencies in aerospace component materials.