ORIGINAL CONTRIBUTION Modeling and Predicting Abrasive Wear Behavior of Al–SiCp Composite Using Multi-response Optimization-Based RSM B. K. Singh 1 . D. Ghosh 2 . N. Mandal 1 . H. Roy 2 Received: 13 February 2018 / Accepted: 4 June 2019 Ó The Institution of Engineers (India) 2019 Abstract In this investigation, different composites of Al– SiCp have been prepared using investment casting route to characterize the tribological properties like abrasive wear and coefficient of friction. The experimental plans are based on central composite design. The effect of process parameters (i.e., applied load, rpm and weight percentage of SiC) on output parameter (i.e., wear rate and coefficient of friction) has been studied. A model based on regression analysis technique has been developed, to predict the response, i.e., wear behavior and coefficient of friction of the metal matrix composites. The adequacy and statistical significance of the developed model have been tested on ANOVA which directly shows the contribution of input parameters on output parameter. Graphical contours are used to study the direct and interaction effects. The finding of results can be concluded as the wear rate diminishes with the increase in % SiCp due to thermal stability of Al matrix which restricts the softening behavior when tem- perature rises. The coefficient of friction shows an increase in value may be due to resistance of sliding action by ceramic particles in the composite. The ANOVA analysis using multi-response optimization of response surface methodology suggests that the optimum results are achieved with 93.32% desirability level, having 15 wt% of SiCp, 2 kg of load and 300 rpm of minimum wear rate and frictional coefficient. Keywords Metal matrix composites (MMC) Á Abrasive wear Á Coefficient of friction Introduction In recent years, development of high strength-to-weight ratio material becomes a primary research topic for the production of lightweight advanced engineering compo- nents, especially for automobile and aerospace companies. To achieve the desired properties for aerospace and auto- mobile applications, metal matrix composite of aluminum has been found to be a potential candidate, where a harder phase as reinforcement is mixed with softer aluminum matrix. It has been illustrated by the number of researchers that aluminum alloys with poor wear resistance application due to its low tribological properties cannot be directly used for automotive components [1, 2]. In order to enhance the wear properties of aluminum, a number of additives such as SiC, TiC, TaC, TiO, MgO, SiO 2 and WC are being reinforced in the form of particles, whiskers or fibers [3, 4]. Many researches [5–15] illustrate that when silicon carbide particulate (SiCp) is reinforced with aluminum alloy, there is a significant improvement in tribological properties like abrasive wear resistance and seizure resistance. Siriyala et al. [16] used Taguchi and Grey relation method to investigate the wear behavior for Al–5%SiCp in MMC and optimized the process parameter. Statistical approach has been used by Basavarajappa et al. [17] to develop a model with different wear parameters, and these authors reported that SiCp-graphite-reinforced composites exhibit less wear in comparison with SiCp-reinforced composites. Sahin & D. Ghosh dghosh@cmeri.res.in; dbs1012000@gmail.com 1 Centre for Advanced Materials Processing, CSIR-Central Mechanical Engineering Research Institute, Durgapur 713209, India 2 NDT & Metallurgy Group, CSIR-Central Mechanical Engineering Research Institute, Durgapur 713209, India 123 J. Inst. Eng. India Ser. D https://doi.org/10.1007/s40033-019-00191-4