Abstract
This work studies the open hole surface integrity of Al 2024-T3/Ti-6Al-4V stacks, which have been subjected to different hole making methods, namely, conventional drilling and helical milling. The resulting hole-exit burr, surface roughness and machined surface/sub-surface microstructures have been characterized and the impact of the hole surface integrity on the fatigue performance of the machined coupons has been revealed. Results show that helical milling can effectively reduce burr formation at hole-exit and cause minimal sub-surface microstructural deformation, especially in the Ti layer. Helical milling produced holes with greater surface roughness, interestingly, the fatigue life of the helical milling coupons doubled that of conventional drilling.
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