Investigation of the Tribological Properties of AlxSi-1.2Fe(Mn) (x = 5-13 wt.%) Alloys

The effect of Fe-impurity and Mn modification on the sliding wear behavior of Al-xSi-1.2Fe(Mn) (x = 5-13 wt.%) alloys was investigated in dry sliding against AISI 52100 steel. According to the results, in the Si range of 5-9 wt.%, Fe-impurity promotes the formation of finely distributed β-Al5FeSi intermetallics in the matrix increasing its hardness and potential to support the tribolayer leading to the improved wear characteristics. The presence of Fe in the composition of Al-(9-13)Si alloys, however, leads to the formation of primary β-platelets that their sizes and volume fractions increase with Si concentration. The formation of primary compounds increases the hardness, but makes the alloys less ductile and more vulnerable to microcracking and wear. Manganese modification converts the β-Fe platelets to the α-Al15(Fe,Mn)3Si2 compounds with different morphologies. The substitution of fine β-platelets by α-Chinese scripts in Al-(5-9)Si-1.2FeMn alloys reduces the wear resistance, but the formation of primary α-compounds with star-like or polyhedral morphologies in Al-(9-13)Si-1.2FeMn alloys improves their wear characteristics. Moreover, it was found that the formation of Fe(Mn)-rich compounds affects the friction coefficient which is likely due to the fracture of particles in the subsurface region, their interaction with contacting surfaces, and their effect on the stability of the tribolayer.