Fabrication and wear behavior of ZTA particles reinforced iron matrix composite produced by flow mixing and pressure compositing

A high chromium cast iron (HCCI) matrix composite reinforced with zirconia-toughened alumina (ZTA) particles was fabricated via rapid-flow mixing followed by high-pressure compositing (FM-PC) technique, which required neither particle coating nor the use of preforms. The microstructure, mechanical properties and impact-abrasion wear resistance of the composite were investigated. The integrity of the composite without obvious defects was demonstrated, a uniform distribution of ZTA particles in the HCCI matrix and a tight mechanically bonded interface between particles and matrix were obtained. The composite exhibited better wear performance than HCCI under different energies, and the relative wear resistance was 2.35 to 1.74 times when the impact energy varied from 1.5 to 4.5 J. The wear mechanisms of the composite were mainly furrow, cutting and fragmentation of reinforced particles under a low impact energy (1.5 J). Conversely, when the impact energy increased to a high value (4.5 J), fragmentation and shedding of the particles, spalling pits and embedding of abrasive particles dominated the wear process.