Experimental, statistical and numerical wear analysis of Al7075/SiC metal matrix composites produced by powder metallurgy

Purpose This study aims to investigate and predict the wear behaviour of powder-metallurgy Al7075/SiC metal matrix composites using experimental testing, statistical modelling and numerical simulation to identify dominant parameters influencing wear and friction performance. Design/methodology/approach Al7075–SiC metal matrix composites with 5, 10 and 15 Wt.% SiC were fabricated by powder metallurgy. Wear tests were performed using a pin-on-disc setup under varying loads, speeds and distances based on a Box–Behnken design. analysis of variance (ANOVA) was used to identify significant parameters affecting wear and friction, and an empirical model was developed. Wear behaviour was also simulated in ANSYS LS-DYNA using Archard’s wear law and validated with experimental results. Findings The results show that increasing SiC content significantly improves the wear resistance of Al7075 composites. ANOVA reveals that sliding distance is the most dominant factor affecting wear and friction, followed by SiC content. The empirical model accurately predicts wear behaviour, and LS-DYNA simulations agree well with experiments, with errors below 5%. Microstructural analysis confirms uniform SiC distribution and reduced abrasive and adhesive wear. Originality/value This study uniquely integrates DOE-based experiments, empirical modelling, and LS-DYNA wear simulations to accurately predict and validate wear behaviour of powder-metallurgy Al7075–SiC composites. Peer review The peer review history for this article is available at: Link to the cited article.