Synergistic Effects of Silicon Carbide and Graphite Reinforcements in AA 2024 Nanocomposites: Unlocking Tribological Efficiency for Eco-Friendly and Economical Industrial Advancements

This study investigates the sliding wear behaviour of AA 2024 nanocomposites designed to enhance tribological efficiency for sustainable and cost-effective industrial applications. The composites were produced incorporating 5 wt.% nano silicon carbide (SiC) and either 5 wt.% or 10 wt.% nano graphite (Gr) as reinforcements, utilizing powder metallurgy and mechanical alloying (MA) techniques. Sintering was conducted at 580 °C for 60 min, followed by uniaxial pressing at 700 MPa. Wear tests were performed under varying loads and sliding distances using a pin-on-disc set-up at ambient temperature. Microstructural analysis confirmed a uniform dispersion of nanoparticles within the matrix. The addition of nano-sized silicon carbide significantly enhanced wear resistance and hardness, while nano graphite contributed to reductions in density and hardness. Field emission scanning electron microscopy (FESEM) provided insights into wear debris morphology and the predominant wear mechanisms. The results indicate that the optimal tribological performance was achieved with a hybrid nanocomposite containing 5 wt.% silicon carbide and 10 wt.% graphite, demonstrating substantial potential for improving wear resistance, reducing friction, and enhancing overall performance in sustainable automotive applications, including engine components, bearings, gears, and brake pads.