Abstract
The application of metal matrix composites (Al-SiC-TiC) in aerospace and defense industries have surged in the areas of hull safety, aviation fins, and closure units. The close to ideal solution for generating powdered mixture availing ball milling, for processing of a metal matrix composite of size 24 × 24 × 5.95 cm3 and composition of 75% Al, 10% SiC, and 10% TiC weight composition is 10:1 ball weight ratio, ball size of 8 mm, rotation speed of 250 rpm, and milling time of 4 h. The powdered mixture is compressed to pellet, sintered for two hours, and further silver coated in a physical vapor deposition setup to surge its electrical conductivity for ease of material removal. To obtain a perfect fit and finish, wire electrical discharge machining cycle has been carried out to machine the component under deionized water and oil + wax + paraffin dielectric mediums in 8 A peak current, 0.45 µs pulse on time, and 45 pulse off time as close to ideal solution, obtained by the technique for the order of preference by similarity to the ideal solution (TOPSIS) analysis. A surge is ascertained in kerf width, material removal rate, and surface roughness in oil + wax + paraffin environment in correlation with deionized water by 0.99–12.78%, 0.18–33.97%, and 2.15–36.86% respectively. The surface morphological study indicates a 32.28%, 42.57%, and 45.73% surge in residual compressive stress, surface roughness and corrosion resistance in oil + wax + paraffin dielectric medium in correlation to deionized water.
Highlights
Materials availed in the defense and aerospace industries are made of high strength Al-SiC composites for disparate applications, corresponding to hull safety, closure units, aviation fins, etc. [1].The material fabricated is taken due to consideration for colossal stresses, hardness, and surface wear for rough terrain applications [2]
This is attributed to the surge in energy of the single pulse discharge directly proportional to Ton [17]
The powdered mixture was compressed to a pellet, sintered for two hours, and further silver coated in a PVD setup to surge its electrical conductivity for ease of material removal
Summary
Materials availed in the defense and aerospace industries are made of high strength Al-SiC composites for disparate applications, corresponding to hull safety, closure units, aviation fins, etc. [1].The material fabricated is taken due to consideration for colossal stresses, hardness, and surface wear for rough terrain applications [2]. Have performed various cutting operations availing mechanical erosion Scientists and researchersand haveultrasonic performederosion) various cutting operations availing mechanical erosion machining, wire electrical discharge machining, and electron beam melting, laser cutting) [8,9,10,11],. (abrasive water jet and ultrasonic erosion) [5,6,7], thermal erosion (electrical discharge machining, wire and chemical erosion (chemicaland erosion and beam electrochemical cutting) [12,13]. For composites oferosion varied electrical discharge machining, electron melting, laser cutting). Of them are significant achieving desired results, wire-electrical discharge (chemicalThough erosioneach and electrochemical cutting)in for composites of varied natures. Though each machining [14]
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