Machinability Study of Al-5Cu-TiB2 In-situ Metal Matrix Composites Fabricated by Flux-assisted Synthesis

Abstract

In-situ composites are multiphase materials where the reinforcing phase is synthesized by a chemical reaction. The reinforcement generated by this route is very small in size and homogeneously distributed in the matrix. Adoption of the engineering application of this material requires a systematic study of machinability characteristics. This work is an attempt to understand the machinability behavior of the Al-5Cu-TiB2 in-situ metal matrix composites fabricated by Flux-assisted Synthesis. The focus of this study is to investigate the effect of the cutting speed and feed rate on flank wear, cutting force, and surface roughness. The contribution of this paper is to study the influence of in-situ-formed TiB2 reinforcement on the machinability of Al-5Cu alloy. It was found that the increase in cutting speed increased the flank wear, reduced the cutting force, and minimized the surface roughness. Increase in the feed rate increased the flank wear, cutting force, and surface roughness. A higher reinforcement ratio increased the tool wear, reduced the cutting force, and increased the surface roughness. These findings can provide suitable machining parameters in turning of Al-5Cu-TiB2 in-situ metal matrix composites.

Share and Cite:

A. Mahamani, "Machinability Study of Al-5Cu-TiB2 In-situ Metal Matrix Composites Fabricated by Flux-assisted Synthesis," Journal of Minerals and Materials Characterization and Engineering, Vol. 10 No. 13, 2011, pp. 1243-1254. doi: 10.4236/jmmce.2011.1013097.

Conflicts of Interest

The authors declare no conflicts of interest.

References

[1] Kuruvilla A.K., Prasad K.S., Bhanuprasad V.V., Mahajan Y.R., “Microstructure-property correlation in Al–TiB2 (XD) composites” Scripta Metall., vol. 24, 1990,pp. 873-878.
[2] Cui C., Shen Y., Meng, F., “Review on fabrication methods of in-situ metal matrix composites” J. Mater. Sci. Tech., vol.16, 2000, pp.619-626.
[3] Ramesh C.S., Ahamed A., Channabasappa B.H.,Keshavamurthy R., “Development of Al 6063–TiB2 in situ composites” Mater.Des., vol.31, 2010, pp. 2230-2236.
[4] Feng C.F., Froyen L., “Microstructures of in-situ Al/TiB2 MMCs prepared by a casting route” J. Mater. Sci., vol.35, 2000, pp.837-850.
[5] Lewis D., “In-situ reinforcement of metal matrix composites: processing and interface” Academic Press, London, 1991, pp 121-150.
[6] Janghorban K., “Processing of ceramic matrix SiC-Al composite” J. Mater. Proc. Techno., vol. 38, 1993, pp. 361-368.
[7] Lakshmi S., Lu L.,Gupta M., “In-situ preparation of TiB2 reinforced aluminum based composites” J. Mater. Proc. Techno., vol. 73, 1998, pp.160-166.
[8] Lee K.T., Lu L., Lai M.O., “Synthesis of in-situ Al–TiB2 composite using stir cast route” Compo. Struct., vol. 47, 1999, pp. 589-593.
[9] Emamy M., Mahta, M., Rasizadeh, J., “Formation of TiB2 particles during dissolution of TiAl3 in Al–TiB2 metal matrix composite using an in-situ technique” Compo. Sci. Techno., vol.66, 2006, pp.1063-1066.
[10] Fan T., Yang G., Zhang D., “Thermodynamic effect of alloying addition on in-situ reinforced TiB2/Al composites” Metallur.Mater. Trans.A, vol.36, pp225-233.
[11] Lu L., Lai M.O., Chen F.L., “Al-4 wt% Cu composite reinforced with in-situ TiB2 particles” Acta Materialia, Vol.10, 1997, pp. 4297-4309.
[12] Liang Y., Zhou J., Dong S., Yang T ., “Thermodynamic analysis of the formation of In-situ reinforced phases in cast Al-4.5Cu alloy” J. Wuhan University of Techno. Mater. Sci. Ed, vol. 23, 2008,pp.342-345.
[13] Herbert M.A., Sarkar C., Mitra R., Chakraborty M., “Microstructural evolution, hardness, and alligatoring in the mushy state rolled cast Al-4.5Cu alloy and in-situ Al4.5Cu-5TiB2 composite” Metall. Mater. Trans. A, vol. 38, 2007, pp. 2110-2126.
[14] Kumar S., Subramanyasarma V., Murty B.S., “High temperature wear behavior of Al–4Cu–TiB2 in-situ composites” Wear, vol. 268, 2010, pp. 1266-1274.
[15] Dabade U.A., Joshi S.S., “Analysis of chip formation mechanism in machining of Al/SiCp metal matrix composites” J.Mater. Proc. Techno., vol. 209,2009,pp. 4704-4710.
[16] Quan Y.M.., Zhou Z.H.,Ye B.Y., “Cutting process and chip appearance of aluminum matrix composites reinforced by SiC particle” J. Mater. Process. Technol.,vol.91,1997, pp.231-235.
[17] Ozcatalbas Y., “Chip and built-up edge formation in the machining of in situ Al4C3–Al composite”. Mater. Des., vol.24, 2003a, pp.215–221.
[18] OzcatalbasY., “Investigation of the machinability behavior of Al4C3 reinforced Al-based composite produced by mechanical alloying technique” Compo. Sci. Technol., vol.63,2003, pp.53–61.
[19] Rai R.N., Datta G.L., Chakraborty M., Chattopadhyay A.B., “A study on the machinability behavior of Al-TiC composite prepared by in-situ technique” Mater. Sci. Eng.: A, vol. 428, 2006, pp.34-40.
[20] Anandakrishnan V., Mahamani A., “Investigations of flank wear, cutting force, and surface roughness in the machining of Al-6061–TiB2 in situ metal matrix composites produced by flux-assisted synthesis” Int J Adv Manuf Technol., vol. 55, 2010,pp.65-73.
[21] Yanming Q., Zehua Z, “Tool wear and its mechanism for cutting SiC particle-reinforced aluminium matrix composites” J. Mater. Proc. Techno., vol. 100, 2000, pp.194-199.

Copyright © 2024 by authors and Scientific Research Publishing Inc.

Creative Commons License

This work and the related PDF file are licensed under a Creative Commons Attribution 4.0 International License.