Tribological Optimization of Al/ZrO₂ Nanocomposites: Influence of Reinforcement Content on Wear Performance Using Taguchi Method
J. Environ. Nanotechnol., Volume 14, No 2 (June 2025) pp. 162-177
Abstract
This study investigates the tribological behaviour of aluminium matrix nanocomposites reinforced with Zirconium dioxide (ZrO₂) nanoparticles, synthesized using the powder metallurgy method. Three different compositions were prepared: AlZ3 (3 wt.% ZrO₂), AlZ6 (6 wt.% ZrO₂), and AlZ9 (9 wt.% ZrO₂), with aluminium as the base matrix. The mechanical mixing was performed using a high-energy ball mill, followed by compaction and sintering in a controlled environment. Wear performance was evaluated using a pin-on-disk tribometer under varying loads and sliding distances. The Taguchi method using an L9 orthogonal array was employed to design the experiments and determine the optimal combination of normal applied load (NAL), sliding distance (SD), and ZrO₂ content for minimizing wear rate, friction coefficient, and specific wear. Additionally, the ANOVA method was employed to identify the key factors influencing wear resistance and to evaluate the significance of their effects. Regression analysis is used to model and predict the relationship between process parameters and better wear resistance. It quantifies the influence of each factor, enabling accurate optimization of conditions for improved wear performance. Taguchi analysis reveals that the optimal conditions are a normal applied load of 30N, sliding distance of 1000 m and 6 wt.% of ZrO2 nano reinforcement. The R² values for wear rate 84.58%, friction factor 87.79%, and specific wear 81.51% indicate strong model fits. These results confirm that the regression models effectively capture the variability in wear performance metrics.
Full Text
Reference
Babu, R. R., Rajendran, C., Saiyathibrahim, A. and Velu, R., Influence of B4C and ZrB2 reinforcements on microstructural, mechanical and wear behaviour of AA 2014 aluminium matrix hybrid composites, Def. Technol., 40, 242–254(2024).
https://doi.org/10.1016/j.dt.2024.05.009
Bennett, S. K., Velmurugan, K. V., Rajendiran, M., Srimathy, G., Devi, D. C., Bohidar, S. K. and Velumayil, R., Optimization of sintering parameters in aluminium metal matrix composites via Taguchi method and ANOVA analysis, AIP Conf. Proc, 3270(1), 20247(2025).
https://doi.org/10.1063/5.0270427
Gajević, S., Miladinović, S., Güler, O., Özkaya, S. and Stojanović, B., Optimization of dry sliding wear in hot-pressed Al/B4C metal matrix composites using Taguchi method and ANN, Mater., 17(16), 4056(2024).
https://doi.org/10.3390/ma17164056
Geng, R., Qiu, F. and Jiang, Q., Reinforcement in Al Matrix Composites: A Review of Strengthening Behavior of Nano‐Sized Particles, Adv. Eng. Mater., 20(9), 1701089(2018).
https://doi.org/10.1002/adem.201701089
Haja, P. S. M., Jayakumar, V., Bharathiraja, G. and Palani, K., Investigations on mechanical and wear behaviour of graphene and zirconia reinforced AA6061 hybrid nanocomposites using ANN and Sugeno-type fuzzy inference systems, Mater. Res. Express., 9(11), 115002(2022).
https://doi.org/10.1088/2053-1591/ac9c86
Kar, A., Sharma, A. and Kumar, S., A Critical Review on Recent Advancements in Aluminium-Based Metal Matrix Composites. Cryst., 14(5), 412(2024).
https://doi.org/10.3390/cryst14050412
Keshavarz, H., Moosavi, S. E., Eslamian, H. and Kokabi, A., Corrosion behavior and tribological-microstructural characterization of Al/ZrO2-Gr hybrid composite fabricated via Friction Stir Processing, J. Alloys Compd., 960, 170770(2023).
https://doi.org/10.1016/j.jallcom.2023.170770
Khazin, M. L., Apakashev, R. A. and Davydov, S. Y., Obtaining Aluminum –Matrix Composite Materials Particulate-Reinforced with Ceramic Particles, Refract. Ind. Ceram., 63(3), 291–296(2022).
https://doi.org/10.1007/s11148-022-00719-4
Kumar, N. and Irfan, G., A review on tribological behaviour and mechanical properties of Al/ZrO2 metal matrix nano composites, Mater. Today. Proc., 38, 2649–2657(2021).
https://doi.org/10.1016/j.matpr.2020.08.240
Manghnani, S., Shekhawat, D., Goswami, C., Patnaik, T. K. and Singh, T., Mechanical and tribological characteristics of Si3N4 reinforced aluminium matrix composites: A short review. Mater. Today. Proc., 44, 4059–4064(2021).
https://doi.org/10.1016/j.matpr.2020.10.440
Manikandan, S. P., Vetrivel, K. P., Thakre, P., Swarnalatha, K., P, N. and Chandrasekar, G., Artificial Neural Network and Taguchi Analysis of Multi-Objective Optimisation of Wear Behaviour of ZrO2 based Aluminium Nanocomposite. 2023 Second International Conference on Electronics and Renewable Systems (ICEARS), 416–421(2023).
https://doi.org/10.1109/icears56392.2023.10084968
Messer, O., Ratzker, B., Shilo, J. T., Kalabukhov, S. and Sokol, M., The effect of coarse and fine Ti3SiC2 particle reinforcement in aluminum matrix composites, J. Alloys Compd., 976, 173150(2024).
https://doi.org/10.1016/j.jallcom.2023.173150
Mu, D. K. Q., Zhang, Z., Xie, Y. H., Liang, J. M., Wang, J. and Zhang, D. L., The microstructures and mechanical properties of a 5vol%SiC/AA2024 nanocomposite fabricated by powder metallurgy, Mater. Charact., 175, 111090(2021).
https://doi.org/10.1016/j.matchar.2021.111090
Nie, Z., Lu, H., Yang, F. and Xu, G., Preparation and property enhancement of SiC particle-reinforced aluminum matrix composites based on Micro-arc Oxidation, J. Alloys. Compd., 1010, 177388(2025).
https://doi.org/10.1016/j.jallcom.2024.177388
Pal, K., Navin, K. and Kurchania, R., Study of structural and mechanical behaviour of Al-ZrO2 metal matrix nanocomposites prepared by powder metallurgy method, Mater. Today. Proc., 26, 2714–2719(2020).
https://doi.org/10.1016/j.matpr.2020.02.570
Pooja, K., Tarannum, N. and Chaudhary, P., Metal matrix composites: revolutionary materials for shaping the future, Discover. Mater., 5(1), 35(2025).
https://doi.org/10.1007/s43939-025-00226-6
Prakash, P. P., Kumar, S. R. and Chauhan, P. S., Analysis and investigation of the efficacy of the nanoparticles on the mechanical properties of aluminium metal matrix composites, A review, Mater. Today. Proc., 103, 76–80(2024).
https://doi.org/10.1016/j.matpr.2023.08.122
Rafiei, J. and Ghasemi, A. R., Development of thermo-mechanical simulation of WC/Inconel 625 metal matrix composites laser cladding and optimization of process parameters, Int. J. Therm. Sci., 198, 108883(2024).
https://dx.doi.org/10.1016/j.ijthermalsci.2024.108883
Ramesh, B. T., Giri, J., Al-Sadoon, M. K., Bongale, A. K., Sathish, T., Banagar, A. R. and others., Optimizing process parameters to minimize wear-induced material loss in bronze-based hybrid metal matrix composites using the Taguchi method, AIP Adv., 14(9), 095104(2024).
https://doi.org/10.1063/5.0203081
Sabari, K., Muniappan, A., Deepanraj, B. and Jinnah, S. M. M., Advanced Mechanical Performance Optimization of Friction Stir Welded AZ31 Magnesium Alloy Using Artificial Neural Network and Grey Relational Analysis, Surf. Rev. Lett., 2550117(2024).
https://doi.org/10.1142/s0218625x25501173
Sabari, K., Muniappan, A., Deepanraj, B. and Mohamed, M. J. S., Enhancing Mechanical Performance of Friction Stir Welded AZ31 Magnesium Alloy with Nano-TiC Reinforcements Using Grey Relational Analysis, Int. J. Precis. Eng. Manuf., 29, e2914(2024).
https://doi.org/10.1590/0104-9224/SI29.14
Sabbar, H. M., Leman, Z., Shamsudin, S. B., Tahir, S. M., Aiza, J. C. N., Hanim, M. A. A., Ismsrrubie, Z. N. and Al-Alimi, S., AA7075-ZrO2 Nanocomposites Produced by the Consecutive Solid-State Process: A Review of Characterisation and Potential Applications, Met., 11(5), 805(2021).
https://doi.org/10.3390/met11050805
Sahoo, S., Jha, B. B. and Mantry, S., Optimization of process parameters of hot consolidated steel matrix composites by Taguchi method, JOM., 76(2), 818–828(2024).
Said, Z., Pandey, A. K., Tiwari, A. K., Kalidasan, B., Jamil, F., Thakur, A. K., Tyagi, V. V, Sarı, A. and Ali, H. M., Nano-enhanced phase change materials: Fundamentals and applications. Progress in Energy and Combustion Science, 104, 101162(2024).
https://doi.org/10.1016/j.pecs.2024.101162
Şenel, M. C., Gürbüz, M. and Koç, E., Fabrication and characterization of aluminum hybrid composites reinforced with silicon nitride/graphene nanoplatelet binary particles. J. Compos. Mater., 53(28–30), 4043–4054(2019).
https://doi.org/10.1177/0021998319853329
Sharma, A. K., Bhandari, R. and Pinca-Bretotean, C., A systematic overview on fabrication aspects and methods of aluminum metal matrix composites, Mater. Today. Proc., 45, 4133–4138(2021).
https://doi.org/10.1016/j.matpr.2020.11.899
Singh, M., Bhandari, D. and Goyal, K., A review of the mechanical performance of nanoparticles reinforced aluminium matrix nanocomposites, Mater. Today. Proc., 46, 3198–3204(2021).
https://doi.org/10.1016/j.matpr.2020.11.191
Singhal, V., Shelly, D., Saxena, A., Gupta, R., Verma, V. K. and Jain, A., Study of the Influence of Nanoparticle Reinforcement on the Mechanical and Tribological Performance of Aluminum Matrix Composites, A Review, Lubr., 13(2), 93(2025).
https://doi.org/10.3390/lubricants13020093
Taha, M. A., Zawrah, M. F. and Abomostafa, H. M., Fabrication of Al/Al2O3/ SiC/graphene hybrid nanocomposites from Al-dross by powder metallurgy: Sinterability, mechanical and electrical properties, Ceram. Int., 48(14), 20923–20932(2022).
https://doi.org/10.1016/j.ceramint.2022.04.084
Tran, D., Lin, C. K., Tung, P. C., Ho, J. R. and Le, T. L., Enhancing mechanical properties of selective-laser-melting TiN/AISI 420 composites through Taguchi GRA and PCA multi-response optimization, J. Mater. Res. Technol., 29, 1278–1292(2024).
https://doi.org/10.1016/j.jmrt.2024.01.174
Vignesh, M., Anbuchezhiyan, G., Mamidi, V. K. and Vivek, A. A., Enriching mechanical, wear and corrosion behaviour of SiO2/TiO2 reinforced Al 5754 alloy hybrid composites, Mater. Lett., 361, 136106(2024).
https://doi.org/10.1016/j.matlet.2024.136106
Vinoth, B., Alagarsamy, S. V., Meignanamoorthy, M., Ravichandran, M., Prediction of tribological performance of AA8011/wt.%ZrO2 based composites fabricated by stir casting route. Proceedings of the Institution of Mechanical Engineers, Part E: J. Process. Mech. Eng., 236(6), 2420–2433(2022).
https://doi.org/10.1177/09544089221096096
Wang, Z., Zhou, M., Jiang, Y., Sui, Y. and Li, Z., Impact-abrasive wear property of ZrO2 toughened Al2O3 ceramic particles reinforced high manganese steel matrix composites, Tribol. Int., 194, 109547(2024).
https://doi.org/10.1016/j.triboint.2024.109547
Wu, D., Zhang, J., Li, W., Xu, Y., Yang, X. and Su, Y., Morphology of ceramic regulates the deposition behavior and mechanical properties of cold spray additive manufactured Al2O3/2024 aluminum matrix composites, Mater. Charact., 215, 114197(2024).
