The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting
Aluminum–Silicon (Al–Si) based materials are commonly preferred in engineering studies requiring high mechanical performance as an alternative to steel materials. These alloys are especially preferred in the automotive industry, aerospace components and heavy machinery parts. In post-casting process...
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Elsevier
2024-11-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785424022804 |
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| author | Şenol Bayraktar Cem Alparslan Nurten Salihoğlu Murat Sarıkaya |
| author_facet | Şenol Bayraktar Cem Alparslan Nurten Salihoğlu Murat Sarıkaya |
| author_sort | Şenol Bayraktar |
| collection | DOAJ |
| description | Aluminum–Silicon (Al–Si) based materials are commonly preferred in engineering studies requiring high mechanical performance as an alternative to steel materials. These alloys are especially preferred in the automotive industry, aerospace components and heavy machinery parts. In post-casting processes, machining operations are of great importance for high geometric precision, surface quality and longer fatigue life in mechanical environments. In this research, the microstructural, mechanical and machining characteristics of the Al–5Si–1Cu–Mg material produced by sand casting method in both as-cast (AC) and heat-treated (HTed) (Solid solution, quenching and aging-SQA) states were experimentally investigated. Microstructural examinations were carried out with optical microscope and SEM images. Mechanical properties were determined by tensile and hardness tests. Then, drilling experiments were performed in the CNC vertical machining center with 8 mm diameter uncoated HSS (High Speed Steel) cutting tools at constant cutting conditions (i.e., cutting speed-V: 125 m/min, feed rate-f: 0.05 mm/rev and depth of cut-DoC: 15 mm). In microstructural investigations, it was determined that the microstructure of the Al–5Si–1Cu–Mg material in AC state consists of α-Al, eutectic Si, β-Fe (β-Al5FeSi) and π-Fe (π-Al8Mg3FeSi6) intermetallics. After the SQA, the existing phases generally exhibited a spherical structure, and it was seen that the β phase in the microstructure transformed into the Ɵ (Al7FeCu2) phase. SQA improved the hardness, yield and tensile durability of the material, whereas decreasing the elongation to fracture. SQA process improved the machining characteristics of the material by decreasing thrust force, moment, surface roughness and built-up edge (BUE) formation. The machined subsurface structure of HTed alloy under constant cutting conditions was determined to be more stable and smooth and the machined surface microhardness of HTed alloy was higher compared to as-cast alloy due to the effect of solid precipitation hardening. In addition, shorter and more broken chips occurred in the machining of HTed alloys due to the effect of low elongation to fracture. |
| format | Article |
| id | doaj-art-c714408627f9419bb00fc8da24663c9b |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
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| series | Journal of Materials Research and Technology |
| spelling | doaj-art-c714408627f9419bb00fc8da24663c9b2024-12-26T08:54:18ZengElsevierJournal of Materials Research and Technology2238-78542024-11-013327642772The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand castingŞenol Bayraktar0Cem Alparslan1Nurten Salihoğlu2Murat Sarıkaya3Mechanical Engineering, Recep Tayyip Erdoğan University, Rize, Turkiye; Corresponding author.Mechanical Engineering, Recep Tayyip Erdoğan University, Rize, TurkiyeMechanical Engineering, Recep Tayyip Erdoğan University, Rize, TurkiyeDepartment of Mechanical Engineering, Sinop University, Turkiye; Faculty of Mechanical Engineering, Opole University of Technology, 45-758, Opole, PolandAluminum–Silicon (Al–Si) based materials are commonly preferred in engineering studies requiring high mechanical performance as an alternative to steel materials. These alloys are especially preferred in the automotive industry, aerospace components and heavy machinery parts. In post-casting processes, machining operations are of great importance for high geometric precision, surface quality and longer fatigue life in mechanical environments. In this research, the microstructural, mechanical and machining characteristics of the Al–5Si–1Cu–Mg material produced by sand casting method in both as-cast (AC) and heat-treated (HTed) (Solid solution, quenching and aging-SQA) states were experimentally investigated. Microstructural examinations were carried out with optical microscope and SEM images. Mechanical properties were determined by tensile and hardness tests. Then, drilling experiments were performed in the CNC vertical machining center with 8 mm diameter uncoated HSS (High Speed Steel) cutting tools at constant cutting conditions (i.e., cutting speed-V: 125 m/min, feed rate-f: 0.05 mm/rev and depth of cut-DoC: 15 mm). In microstructural investigations, it was determined that the microstructure of the Al–5Si–1Cu–Mg material in AC state consists of α-Al, eutectic Si, β-Fe (β-Al5FeSi) and π-Fe (π-Al8Mg3FeSi6) intermetallics. After the SQA, the existing phases generally exhibited a spherical structure, and it was seen that the β phase in the microstructure transformed into the Ɵ (Al7FeCu2) phase. SQA improved the hardness, yield and tensile durability of the material, whereas decreasing the elongation to fracture. SQA process improved the machining characteristics of the material by decreasing thrust force, moment, surface roughness and built-up edge (BUE) formation. The machined subsurface structure of HTed alloy under constant cutting conditions was determined to be more stable and smooth and the machined surface microhardness of HTed alloy was higher compared to as-cast alloy due to the effect of solid precipitation hardening. In addition, shorter and more broken chips occurred in the machining of HTed alloys due to the effect of low elongation to fracture.http://www.sciencedirect.com/science/article/pii/S2238785424022804Al-5Si–1Cu–Mg alloyMicrostructureMechanical propertiesMachinability characteristicsHeat treatment |
| spellingShingle | Şenol Bayraktar Cem Alparslan Nurten Salihoğlu Murat Sarıkaya The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting Journal of Materials Research and Technology Al-5Si–1Cu–Mg alloy Microstructure Mechanical properties Machinability characteristics Heat treatment |
| title | The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting |
| title_full | The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting |
| title_fullStr | The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting |
| title_full_unstemmed | The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting |
| title_short | The impact of heat treatment process on the drilling characteristics of Al–5Si–1Cu–Mg alloy produced by sand casting |
| title_sort | impact of heat treatment process on the drilling characteristics of al 5si 1cu mg alloy produced by sand casting |
| topic | Al-5Si–1Cu–Mg alloy Microstructure Mechanical properties Machinability characteristics Heat treatment |
| url | http://www.sciencedirect.com/science/article/pii/S2238785424022804 |
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