Optimizing Wear Characteristics of Aluminium Powder Reinforced Epoxy Polymer Matrix Composite Using Taguchi Grey Relational Analysis Approach

Aluminium-epoxy composites, known for their improved mechanical and tribological properties, exhibit significant potential in various engineering applications. This study investigates the wear behaviour of these composites with a focus on optimization for improved performance. An appropriate manufacturing approach was utilized in order to incorporate aluminum particles into an epoxy matrix as part of the fabrication process. An apparatus that was specifically designed for testing was utilized in order to assess the wear characteristics. For the purpose of designing trials and optimizing the parameters of the wear process, Taguchi's approach was applied. Zircon particles were found to be distributed uniformly throughout the Al-epoxy composites, as demonstrated by the visual evidence obtained from scanning microscopy samples. Statistical analysis revealed that the factor load is the most significant contribution to wear, accounting for roughly 5.67% of the observed wear. Sliding distance, speed, and composite load were determined to be the next most significant contributors to wear. Finding the COF in composites can be accomplished by the use of a prediction tool that is the regression equation that was generated from the data. According to the GRA response table, the best set of parameters for improving the wear properties is as follows: the applied load should be 35 N, the sliding speed should be 250 m/s, and the sliding distance should be approximately 1650 m. A scanning electron microscopy examination of the surface that had been worn revealed that the Al-epoxy composite had exhibited steady wear with the parameters adjusted to their ideal values. © The Institution of Engineers (India) 2024.