Optimizing the tribological parameters of Fe/ZrO2 composite

Abstract

Iron-based metal matrix composites have shown promising potential as bearing materials for various tribological applications, and hence attained the interest of the researchers. Therefore, an attempt has been made to examine the outcome of certain process variables upon the frictional properties of Fe-ZrO2 metal matrix composite (MMC) developed via powder metallurgy (PM). The experimental design for the applicable wear tests was carried out according to a face-centred central composite design (FCCD) utilizing response surface methodology (RSM). The tribological performance was assessed under various operating parameters of applied load (5–10 N), sliding speed (0.75–1.25 m/s) and sliding distance (200–600 m) using a pin-on-disc tribometer. The significance of the process variables upon the responses (coefficient of friction and wear rate) was investigated using analysis of variance technique. The regression equations were generated, and confirmatory experiments were executed using new parametric conditions to ensure the sufficiency of the developed models. Surface and contour plots depict the increment in coefficient of friction initially, and then decrement, while the wear rate is seen to be increasing at all levels of process variables. Moreover, the microstructures of the composite and worn surface morphology were investigated using various microstructural characterization techniques. © IMechE 2025.