Experimental Evaluation of Process Parameters Effect on Mechanical and Machining Properties of Al6061–Cu–SiCp-Reinforced Metal Matrix Composite

Abstract

The present analysis emphasizes on optimization of pouring speed, stirring speed and pouring temperature for mechanical properties and machining properties of aluminium metal matrix composites. In Al6061 aluminium, alloy presence of Mg improves the wettability with SiCp. Precipitation hardening was also achieved; furthermore, the addition of 4 % Cu is more or less admired to duralumin that has precipitation hardening phenomenon when it is added above 560°C. Precipitation hardening prevents dislocation at the molecular level and improves the strength of the material. Five levels of pouring speeds and two types of material meant that matrix alloy and metal matrix composites [i.e. Al6061 + 4 % Cu and Al6061–4 % Cu–5 % SiCp-reinforced metal matrix composite processed using stir-casting technique] are under consideration as an input parameter. In the second experimentation, five levels of stirring speed and five levels of pouring temperatures at a constant pouring speed of 2.5 cm/s were considered as an input parameter throughout. Outputs are: hardness, impact strength and metal removal rate through electron discharge machining of metal matrix composites casting for each experiment. It ought to be over that metal that metal matrix composite is best in terms of hardness, impact strength and machining ability, compared to base matrix alloy in any respect of pouring speeds. The optimum worth of hardness, impact strength and higher metal removal rate is ascertained whether the pouring speed varies from 2 to 3 cm/s for metal matrix composite. It is inferred from the second section of the experiments that a pouring temperature range of 700–750 °C and 400–600 rpm stirring speed offers higher worth of mechanical [hardness and impact strength] and machining properties. The scanning electron micrographs [SEM] shows the result of pouring speeds, stirring speed and pouring temperature of metal matrix composites.