Investigation of Mechanical and Wear Characteristics of Graphite-Reinforced Aluminum Alloy Matrix Composites for Aerospace Applications

The present study addresses the increasing demand for lightweight, high-strength composite materials with enhanced mechanical performance for aerospace and aircraft applications. The ability of graphite particulates on the dry sliding wear behavior of aluminium alloy AA2195 graphite composites has been evaluated using pin-on-disc tools. The materials were fabricated by medium-frequency casting technique. Composites with 6 wt% graphite particles were processed. The casted composites were subjected to T6 heat treatment. The effect of sliding speed and sliding distance has been studied under dry sliding conditions. The hardness of the composites is measured using Micro hardness tester and their tensile strength is measured using a universal testing machine. The wear rate of the composites reduced with the addition of graphite content and reached a minimum with 6 wt% graphite content. The coefficient of friction is decreased with the addition of graphite content and reached a minimum at 6 wt% graphite. The effect of graphite on hardness and tensile strength is also studied. The AA2195 aluminum alloy exhibited its probable to act effectively as a selflubricating material under dry sliding conditions in the lower range of graphite content, and 6 wt% graphite appeared to be optimum.

Graphite content varied from 2% to 8%, with the AA2195-6%Gr composite achieving the highest tensile strength and yield strength. Hardness peaked at 6% graphite. Tribological tests showed improved wear resistance at higher graphite levels, with the AA2195-6%Gr composite exhibiting the lowest wear rate. These findings highlight potential for sustainable fabrication of high-performance aluminum composites.