Parametric Study on the Tribological Response of WAAM-deposited Aluminium 8090/Nano-TiC Metal Matrix Composites
J. Environ. Nanotechnol., Volume 15, No 1 (March 2026) pp. 78-90
Abstract
Wire Arc Additive Manufacturing (WAAM) offers a promising route for fabricating large-scale aluminium components. However, the tribological performance of WAAM-processed aluminium alloys remains a critical limitation for wear-sensitive applications. In this study, Aluminium 8090 alloy reinforced with 1 wt.% nano-sized titanium carbide (TiC) was fabricated using the WAAM process, and its tribological behaviour under dry sliding conditions was systematically investigated. A Taguchi L27 orthogonal array was employed to evaluate the influence of the applied load, sliding velocity, and sliding distance on the wear rate and coefficient of friction (COF). Statistical tools, including signal-to-noise ratio analysis, analysis of variance, contour plots, and regression modelling were used to identify the dominant wear-controlling parameters and optimize the operating conditions. The results revealed that sliding velocity was the most influential parameter affecting both wear rate and COF, followed by applied load, while sliding distance exhibited a comparatively minor effect. The incorporation of nano-TiC significantly enhanced the load-bearing capacity, resulting in improved hardness and reduced wear under moderate operating conditions. The SEM analysis of the worn surfaces indicated a transition from mild adhesive wear at lower loads to abrasive and fatigue-dominated wear at higher loads, corroborating the experimental and statistical findings. The developed regression models demonstrated good predictive capability within the investigated parameter range. This study established clear structure–property–performance correlations and demonstrated the potential of WAAM-fabricated Al8090–nano-TiC composites for wear-critical engineering applications.
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