Fabrication and characterization of ZrO2 reinforced Fe-20Cr alloy composites

The reinforcement effects of the ZrO2 and the wear and mechanical behaviour of (Fe,Cr)-based alloy composites were investigated. The (100-x) (Fe80Cr20) -(x) ZrO2 composites were fabricated via powder metallurgy. The iron-chromium and ZrO2 powders were efficiently milled and mixed in ball mill. In the Fe80Cr20 alloy, the effect was investigated by changing the ZrO2 composition by 5%, 10%, and 15%. The blended powder mixture was cold compacted and sintered at 1030 degrees C. Scanning electron microscopy (SEM), elemental mapping, and x-ray diffraction techniques were utilized to assess the microstructural properties of the sintered composites. In addition, the mechanical properties such as hardness, flexural strength, and porosity were examined with variations in ZrO2 composites. The dry sliding wear tests with various normal loads and a constant sliding distance were used to find the composite's wear behaviour. The composite containing 10% ZrO2 has shown the maximum flexural strength with 1470 MPa, and hardness 359.8 HV10 respectively, compared to 5% ZrO2 and 15% ZrO2. With a concentration of 10 wt.% ZrO2, the wear resistance is found to be significantly enhanced, while after 10 wt.% ZrO2, its properties deteriorate. In addition to having improved interfacial bonding, lower porosity, and microstructure uniformity, Fe80Cr20 (Fe-20 Cr) -10 wt% ZrO2 composites exhibit superior mechanical properties compared to other materials.