Mechanical properties and two-body abrasion wear behaviour of Al–5Cu–2Ni/FeNb (0–5 wt.%) composites synthesised through powder metallurgy

The Al5Cu2Ni alloy was synthesised by powder metallurgy with FeNb reinforcement (0–5 wt.%). The hot-compaction process parameters were set to a compaction pressure of 550 MPa, a sintering temperature of 450°C, and a sintering time of 90 min. Ferroniobium (FeNb) was selected for its high strength, wear resistance, and high-temperature stability. Abrasive dry sliding wear tests were conducted using a 220-grit SiC emery sheet as the counter body, with applied load, sliding velocity, and sliding distance set to 15 N, 1 m/s, and 75 m, respectively. The results showed that the yield and ultimate compressive strengths increased considerably to 354–474 MPa and 528–623 MPa, respectively. The specific wear rate decreased notably from 56.72 × 10−3 to 36.8 × 10−3 mm³/Nm. However, at 5 wt.% FeNb, the results exhibited a monotonic trend. The micro-Vickers hardness of Al5Cu2Ni/xFeNb composites increased significantly, from 124.9–177.4 HV, with FeNb reinforcement. Metallographic analysis revealed fine, core-shell microstructures that indicate superior densification and a refined microstructure, confirming that the composites exhibit enhanced strength and exceptional wear resistance compared to the base alloy.