Investigations into wear and galling mechanism of aluminium alloy-tool steel tribopair at different temperatures

• The tribosystem aluminium alloy-tool steel at temperatures up to 450 °C has been investigated.
• Wear mechanisms at different temperatures range from severe abrasive wear to material transfer.
• System temperature plays a major role in determining the generated wear mechanism.
• Increasing surface roughness from Ra 0.1 µm to Ra 0.4 µm affects material transfer micromechanisms.

Aluminium alloys show poor formability at room temperature, and the production of complex components requires a series of high temperature forming processes, such as warm and hot forging, extrusion and hot sheet metal forming. Forming aluminium in these conditions subjects the tools to severe adhesive wear and galling, leading to increased energy needs, shorter tool life, lower part quality and increased cost. In this work, the wear mechanisms generated by aluminium alloys on forming tools have been studied by means of linear reciprocating sliding tests. Aluminium alloy AA2017 balls were slid against DIN 1.2344 (AISI H13) tool steel samples with various surface finishes at temperatures up to 450 °C. The main results show that the observed wear mechanisms are extremely dependent on the system temperature, ranging from pure abrasive wear to formation of layers of compacted aluminium debris and gross aluminium transfer in the form of lumps. On the other hand, tool surface finish has a limited effect on gross material transfer, but does affect the material transfer micromechanisms.