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

S. Kathiravan; R. Thanigaivelan; P. Suresh

doi:10.2478/msp-2022-0036

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

Materials Science-Poland

Volume 40 (2022): Issue 3 (September 2022)

By: S. Kathiravan, R. Thanigaivelan and P. Suresh

Open Access

|Dec 2022

Figures & Tables

Table 1

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

Table 2

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

[i] GGBS, ground granulated blast furnace slag

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

Table 3

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

Table 4

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

[i] MRR, material removal rate; OA, orthogonal array; SR, surface roughness

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

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: Al6061–5% 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

Table 5

Elemental results of EDX analysis

S. No.	Element	2.5% of GGBS		5.0% of GGBS		7.5% of GGBS
S. No.	Element	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

[i] EDX, energy-dispersive X-ray; GGBS, ground granulated blast furnace slag

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

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

Table 6

S/N ratio for MRR and SR

Levels	Parameters
Levels	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

[i] MRR, material removal rate; SR, surface roughness

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

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

References

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Articles in this issue

DOI: https://doi.org/10.2478/msp-2022-0036 | Journal eISSN: 2083-134X (formerly 2083-124X) | Journal ISSN: 2083-1331

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Language: English

Page range: 112 - 124

Submitted on: Oct 3, 2022

Accepted on: Dec 29, 2022

Published on: Dec 31, 2022

Published by: Wroclaw University of Science and Technology

In partnership with: Paradigm Publishing Services

Keywords:

aluminum,

stir casting,

metal-matrix composites,

Taguchi,

optimization

Related subjects:

Materials sciences,

Materials sciences, other,

Nanomaterials,

Functional and smart materials,

Materials characterization and properties

© 2022 S. Kathiravan, R. Thanigaivelan, P. Suresh, published by Wroclaw University of Science and Technology
This work is licensed under the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 License.

Volume 40 (2022): Issue 3 (September 2022)

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

Figures & Tables

Table 1

Table 2

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Table 3

Table 4

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Table 5

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Table 6

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