Dry Sliding Wear Properties of Rheo-diecasting Hypereutectic Al-Si Alloy with High Iron Content

The dry sliding wear tests of Al-17Si-2Fe-2Cu-1Ni-0.8Mn alloy produced by rheo-diecasting (RDC) process assisted with ultrasonic vibration were carried out over a pin-on-disk wear tester. The results show that the wear rate of the RDC alloy was lower than that of the alloy produced by liquid die casting (LDC) process under the same applied load. The refinement of coarse plate-like δ-Al₄(Fe, Mn)Si₂ phase and the elimination of porosities improved the wear resistance of RDC alloy. The wear rates of the LDC and RDC alloys increased sharply from 50 N to 100 N and from 150 N to 200 N. For the LDC and RDC alloys, oxidation wear was the dominant mechanism at 50 N. From 100 N to 150 N, oxidation wear and delamination wear were the main wear mechanism. At 200 N, delamination wear was the dominant wear mechanism.