Abstract
In the present work, free-cutting aluminum alloy AA6026 with 1.1 wt.% bismuth addition was fabricated by different melt preparation methods in order to investigate whether the melt preparation route affects the solidification sequence and thus has an influence on the machinability of the alloy. All experiments were designed to simulate variable industrial conditions: addition of bismuth in an induction melting furnace, addition of bismuth in an electric resistance holding furnace, addition of bismuth together with grain refiner, effect of holding time and melt temperature before casting. Detailed thermodynamic analyses (DSC, Thermo-Calc) and microstructural characterization (SEM-EDS, XRD) have been performed to explain the solidification sequence, microstructure development and especially formation of the intermetallic Mg3Bi2 phase.
Highlights
Aluminum 6xxx Alloy with BismuthThe ease with which a metal can be machined by cutting is described as machinability and is one of the key factors affecting its utility for a certain product
The aim of this research was to investigate whether the melt preparation route affects the solidification sequence of the Pb-free aluminum alloy AA6026 with 1.1 wt.% bismuth addition and has an influence on the machinability of the alloy
Bismuth was added to an aluminum AA6026 alloy as a replacement for the lead which is commonly used for improving the machinability
Summary
Aluminum 6xxx Alloy with BismuthThe ease with which a metal can be machined by cutting is described as machinability and is one of the key factors affecting its utility for a certain product. Aluminum alloys are generally considered to have good machinability compared to ferrous alloys. Their ductility and tendency to form very long stringy chips, which build-up at the cutting tool edge, are responsible for poor surface finish, high machining forces and lower productivity. The most important free-cutting aluminum alloys came from the 2xxx and 6xxx series with additions of lead or combinations of lead, bismuth, and tin. Even stricter measures have been imposed (RoHS 3 Pb < 0.1 wt.%), forcing manufacturers to develop new free-cutting aluminum alloys without the addition of lead
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