Characterization and Defect Analysis of Machined Regions in Al-SiC Metal Matrix Composites Using an Abrasive Water Jet Machining Process

Abstract

Metal matrix composite (MMC) materials are increasingly used in industrial sectors such as energy, structural, aerospace, and automotive. This is due to the improvement of properties by the addition of reinforcements. Thus, it is possible to obtain properties of higher strength, better rigidity, controlled thermal expansion, and elevated wear resistance. However, due to the extreme hardness achieved during their manufacture, these composites pose a challenge to the conventional machining industry due to the rapid deterioration experienced by cutting tools. This article therefore proposes the use of an unconventional machining method that is becoming increasingly widely used: abrasive water jet cutting. This process is characterized by high production rates, absence of wear, and environmental friendliness, among other advantages. Experimental tests were carried out in order to analyze results that minimize the formation of defects in the machining of metal matrix composite consisting of aluminium matrix with silicon carbide (Al-SiC MMC). To this end, results were analyzed using Scanning Optical and Electron Microscope (SOM/SEM) techniques, the taper angle was calculated, and areas with different surface quality were detected by measuring the roughness.

Effect of ceramic particle reinforcement type and process parameters on abrasive water jet processing of aluminum metal matrix composites fabricated by stir casting and hot rolling

“…The decrease in the depth of cut and negative effect on the surface quality were expected in the AWJ process and are consistent with the results presented in literature. 11,26,34 The negative effect on the SR with an increase in the depth of the cut could be attributed to numerous causes, such as the reduction in the jet energy, the decrease in the number of particles involved in the process by embedding the abrasive particles in the workpiece, the loss of sharpness of the abrasive particles, and the change in the angle of impact of the abrasive particles. Macro and micro imaging of kerf surfaces displaced in Figure 5 details the effect of particle reinforcement on the kerf surface during AWJ machining.…”

“…The force exerted during the process and the residual stresses that occur after the process are low during AWJ processing, which ensures high machining capacity. 7,10–13 Gnanavelbabu et al changed the B 4 C and CNT reinforcement ratios of the AA6061-B 4 C–CNT composite material between 5% and 15% by volume and revealed that both surface roughness (SR) and kerf taper angle (KTA) were negatively affected by the increase in the B 4 C reinforcement ratio. 13…”

A Review on the Abrasive Water-Jet Machining of Metal–Carbon Fiber Hybrid Materials

“…These mechanisms do not act separately, but in combination. In this way, the final cuting effect is generated by the geometric superposition of craters formed by the particles that have impacted the material [37,38]. It is necessary to differentiate between the behavior of ductile materials and fragile materials, since due to their different properties they show different behaviors [28,39].…”

Literature Review on Abrasive Jet Machining - Past and Present

“…As the globe advances technologically in the fields of space exploration, missiles, and nuclear power, these businesses demand extremely intricate and accurate components that meet specific specifications and AJM will prove helpful to them. [13][14][15][16][17][18].…”