Characterization of microstructure and wear behavior of nickel modified Zn-27%Al alloy casting

Improvement of mechanical and tribological behaviors of zinc-based die cast alloy is necessary for bearing applications,and chemical modification is found to be a good choice.Chemical modification of Zn-27wt.%Al alloy was carried out with 1%,2%and 3%nickel through casting route,and its effect on microstructure,hardness,and dry sliding wear behavior was investigated.Significant refinement of dendritic microstructure is observed along with a transformation from rosette to near rounded morphology with the increase in nickel content of base alloy.With 1%nickel modification,an aluminum-rich Al_(3)Ni intermetallic compound of string type forms in inter dendritic region,while with 2%and 3%nickel modifications,a nickel-rich AlNi3 intermetallic compound of lath/plate type is formed within the intra dendritic region.Hardness of the base alloy is improved through grain boundary strengthening at a lower concentration of nickel,and particulate strengthening and spinodal decomposition are the reason for increase in hardness of the alloy with a higher content of nickel.Coefficient of friction and wear rate of base alloy is decreased with increasing nickel amount.Worn surface is characterized by delamination,smearing and grooving.The wear mechanism is transferred from adhesion to abrasive via oxide film formation with an increase in amount of nickel.