Roller Burnishing of Particle Reinforced Aluminium Matrix Composites

Abstract

Energy and resource efficient systems often demand the use of light-weight materials with a specific combination of properties. However, these requirements usually cannot be achieved with homogeneous materials. Consequently, composites enabling tailored properties gain more and more importance. A special kind of these materials is aluminium matrix composites (AMCs), which offer elevated strength and wear resistance in comparison to the matrix alloy. However, machining of these materials involves high tool wear and surface imperfections. An approach to producing high-quality surfaces consists in roller burnishing of AMCs. Furthermore, such forming technologies allow for the generation of strong compressive residual stresses. The investigations address the surface properties in the roller burnishing of AMCs by applying different contact forces and feeds. For the experiments, specimens of the alloy AA2124 reinforced with 25% volume proportion of SiC particles are used. Because of the high hardness of the ceramic particles, roller bodies were manufactured from cemented carbide. The results show that roller burnishing enables the generation of smooth surfaces with strong compressive residual stresses in the matrix alloy. The lowest surface roughness values are achieved with the smallest feed (0.05 mm) and the highest contact force (750 N) tested. Such surfaces are supposed to be beneficial for components exposed to dynamic loads.

Joining metrics enhancement when combining FSW and ball-burnishing in a 2050 aluminium alloy

“…Therefore, the highest average surface roughness (2.04 μm) is listed for higher values of feed and pressure with a parallel strategy and thermal treatment after the FSW process, whereas the best surface quality (0.08 μm of Ra) is found for the opposite configuration, i.e., the lowest values of feed and pressure with a perpendicular strategy and thermal treatment before the FSW process. Comparable results have been recently reported by Nestler and Schubert [14] when studying the rolling burnishing process of an aluminium alloy with silicium carbide (SiC) embedded particles. They described how the surface roughness increases when large radial feeds and burnishing forces are used.…”

Prediction of Surface Integrity Parameters in Roller Burnishing of Ti6Al4V

“…Several studies have been conducted to investigate the effects of different process parameters (feed, speed, tool geometry and material, etc.) and lubri-coolant conditions [1][2][3] on the surface aspect during severe plastic deformation processes and burnishing [4][5][6][7][8][9][10][11][12][13][14].…”

The Experimental and Numerical Research for Plastic Working of Nickel Matrix Composite Coatings

“…The burnishing process is a surface plastic working technique that is known by researchers and scientists, but first of all research is carried out on single-layer materials [17][18][19][20][21][22][27][28][29][44][45][46][47][48][49][50][51] and not for coated materials. Therefore, and based on our own research, an experimental analysis of the burnishing of products with the applied alloy and composite coatings was undertaken.…”