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Due to light weight, high specific strength, high corrosion resistance and good heat transfer ability, aluminium alloys are becoming attractive for critical structural applications. These alloys can be manufactured using powder metallurgy techniques in which porosity is a common characteristic. The presence of pores is responsible for decreasing effective load bearing cross sectional area and inducing stress concentration sites for strain localization and damage, decreasing both strength and ductility. The present study aims to establish a better understanding of the relationship between surface porosity and corresponding wear behavior. In this study, porous specimens were produced using powder metallurgy technique and the extent of wear damage and the type of wear was investigated under low load range of 1.5 - 5 N against AISI 52100 bearing steel ball using a reciprocating ball-on-flat configuration and frequency of 10 Hz. Scanning electron microscopy of the wear tracks and wear debris was carried out to understand wear mechanisms. This study revealed that due to combined effect of high stress intensity and subsurface cracking, wear rate increases with increasing porosity content. The friction and wear behavior of pure Al and Al 6061 as a function of porosity content can be attributed to their hardness and corresponding wear mechanism.

Effect of Surface Porosity on Tribological Properties of Sintered Pure Al and Al 6061