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Fabrication, microstructure, and machinability of aluminum metal-matrix composites

S. Kathiravan
S. Kathiravan
, 
R. Thanigaivelan
R. Thanigaivelan
 y 
P. Suresh
P. Suresh
   | 31 dic 2022
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Publicado en línea: 31 dic 2022
Páginas: 112 - 124
Recibido: 03 oct 2022
Aceptado: 29 dic 2022
DOI: https://doi.org/10.2478/msp-2022-0036
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© 2022 S. Kathiravan et al., published by Sciendo
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License.

Fig. 1

Representation of Al composite fabrication.GGBS, ground granulated blast furnace slag
Representation of Al composite fabrication.GGBS, ground granulated blast furnace slag

Fig. 2

Steps in machining process
Steps in machining process

Fig. 3

(A) GGBS reinforcement particles; (B) Different percentages of GGBS. GGBS, ground granulated blast furnace slag
(A) GGBS reinforcement particles; (B) Different percentages of GGBS. GGBS, ground granulated blast furnace slag

Fig. 4

SEM image of Al6061–2.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy
SEM image of Al6061–2.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy

Fig. 5

SEM image of Al6061–5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy
SEM image of Al6061–5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy

Fig. 6

SEM image of Al6061–7.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy
SEM image of Al6061–7.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy

Fig. 7

Optical image of Al6061–7.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag
Optical image of Al6061–7.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag

Fig. 8

SEM and EDX profile analysis for the surfaces: Al6061–2.5% of GGBS reinforcement. EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy
SEM and EDX profile analysis for the surfaces: Al6061–2.5% of GGBS reinforcement. EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag; SEM, scanning electron microscopy

Fig. 9

SEM and EDX profile analysis for the surfaces: Al6061–5% of GGBS reinforcement. EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag; SEM; scanning electron microscopy
SEM and EDX profile analysis for the surfaces: Al6061–5% of GGBS reinforcement. EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag; SEM; scanning electron microscopy

Fig. 10

SEM and EDX profile analysis for the surfaces: Al6061–7.5% of GGBS reinforcement. EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag; SEM; scanning electron microscopy
SEM and EDX profile analysis for the surfaces: Al6061–7.5% of GGBS reinforcement. EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag; SEM; scanning electron microscopy

Fig. 11

XRD pattern for the surfaces: Al6061–2.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; XRD, X-ray diffraction analysis
XRD pattern for the surfaces: Al6061–2.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; XRD, X-ray diffraction analysis

Fig. 12

XRD pattern for the surfaces: Al6061–5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; XRD, X-ray diffraction analysis
XRD pattern for the surfaces: Al6061–5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; XRD, X-ray diffraction analysis

Fig. 13

XRD profile analysis for the surfaces: Al6061–7.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; XRD, X-ray diffraction analysis
XRD profile analysis for the surfaces: Al6061–7.5% of GGBS reinforcement. GGBS, ground granulated blast furnace slag; XRD, X-ray diffraction analysis

Fig. 14

Average S/N ratio for MRR. MRR, material removal rate
Average S/N ratio for MRR. MRR, material removal rate

Fig. 15

Average S/N ratio for SR. SR, surface roughness
Average S/N ratio for SR. SR, surface roughness

Fig. 16

Effect of parameters on (A) feed rate with depth of cut on MRR (B) feed rate with percentage of reinforcement composition on SR (C) percentage of reinforcement composition with spindle speed on SR (D) percentage of reinforcement composition with depth of cut on SR
Effect of parameters on (A) feed rate with depth of cut on MRR (B) feed rate with percentage of reinforcement composition on SR (C) percentage of reinforcement composition with spindle speed on SR (D) percentage of reinforcement composition with depth of cut on SR

Fig. 17

Evaluation profile of SR on (A) 2.5% of reinforcement composition, (B) 5.0% of reinforcement composition, and (C) 7.5% of reinforcement composition. SR, surface roughness
Evaluation profile of SR on (A) 2.5% of reinforcement composition, (B) 5.0% of reinforcement composition, and (C) 7.5% of reinforcement composition. SR, surface roughness

The milling process's parameters and their levels

Symbol Factors Level 1 Level 2 Level 3
A Spindle speed (rpm) 1,000 1,250 1,500
B Feed rate (mm/min) 220 240 260
C Depth of cut (mm) 0.25 0.50 0.75
D Percentage of composition 2.5 5.0 7.5

Al6061 chemical composition in percentage

Mg Si Fe Cu Cr Zn Mn Ti Al
1.20 0.80 0.70 0.40 0.35 0.25 0.15 0.15 96

GGBS chemical composition in percentage

SiO2 CaO Al2O3 Mg O SO3 K2O Fe2O3 Na2O
34.4 33.2 21.5 9.5 0.47 0.39 0.2 0.34

Elemental results of EDX analysis

S. No. Element 2.5% of GGBS 5.0% of GGBS 7.5% of GGBS
Weight (%) Atomic (%) Weight (%) Atomic (%) Weight (%) Atomic (%)
1 O K 11.23 18.27 18.27 28.22 41.44 55.62
2 Na K 39.28 47.97 0.49 0.53 3.31 3.09
3 Al K 33.98 24.60 71.31 65.31 42.72 34.00
4 Si K 3.05 2.59 3.67 3.23 6.41 4.90
5 Cl K 6.35 4.42 0.44 0.31 0.48 0.29
6 Mn K 0.37 0.21 1.20 0.54 1.88 0.74
7 Fe K 2.00 0.71 1.05 0.47 1.82 0.70
8 Cu K 1.95 0.68 0.94 0.36 1.93 0.65

Design of experiment using L9 OA

Experimental No. A B C D MRR (mm3/min) SR (μm)
1 1000 220 0.25 2.5 880 0.344
2 1000 240 0.50 5.0 1,920 0.340
3 1000 260 0.75 7.5 3,120 0.328
4 1250 220 0.50 7.5 1,760 0.343
5 1250 240 0.75 2.5 2,880 0.332
6 1250 260 0.25 5.0 1,040 0.356
7 1500 220 0.75 5.0 2,640 0.347
8 1500 240 0.25 7.5 960 0.347
9 1500 260 0.50 2.5 2,080 0.314

S/N ratio for MRR and SR

Levels Parameters
A B C D A B C D
MRR in mm3/min SR in μm
Level 1 64.81 64.08 59.63 64.81 9.441 9.252 9.144 9.636
Level 2 64.81 64.83 65.65 64.81 9.281 9.380 9.575 9.178
Level 3 64.81 65.53 69.17 64.81 9.483 9.572 9.484 9.390
Delta 0.00 1.45 9.54 0.00 0.202 0.320 0.431 0.458
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