Tailored mechanical and tribological response of Al–WC composites synthesized via powder metallurgy

This study investigates the mechanical and tribological performance of aluminium tungsten carbide (Al-WC) composites fabricated via the powder metallurgy (P/M) route. Pure aluminium was reinforced with varying weight percentages of micro-sized WC particles (0, 3, and 6 wt%) to evaluate the effects on hardness, density, and erosion wear resistance. Microstructural analysis revealed a uniform distribution of WC particles and refined grain morphology with increasing reinforcement content. The composites demonstrated a significant improvement in hardness, with values rising from 50 HV for pure Al to 73 HV for Al-6WC. Erosion wear testing under different impingement angles (i.e., 30, 45, 60, and 90 °) and velocities (i.e., 30, 50, 70, and 90 m/s) revealed that the addition of WC altered the wear mechanism from ductile to brittle, particularly at higher impact angles and velocities. Al-3WC exhibited optimal erosion resistance at intermediate conditions, while Al-6WC showed localized embrittlement and particle-matrix debonding at extreme erosive loads. XRD and EDS analyses confirmed the retention of WC phases and their uniform dispersion within the matrix. The optimized WC content is critical for tailoring composite performance in dynamic and abrasive environments.