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

Kathiravan, S.; Thanigaivelan, R.; Suresh, P.

doi:10.2478/msp-2022-0036

Figures & Tables

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

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

SEM image of Al6061–2.5% 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

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

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

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

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

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: Al6061–5% 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

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

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

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

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

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

Figures & Tables

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