Experimental investigation on synthesis characterization and machining of aa6061 tic composites using electric discharge machining

Abstract

Aluminium Alloy (AA) 6061 based ceramic reinforced composites are widely used in many engineering applications because of its high strength to low weight behaviour. For engineering applications, the ceramic reinforced composites are commonly machined using non-traditional machining process compared to traditional machining process. Since, the abrasive ceramic particles in the composites may damage the tool material and surface quality of the product. Electrical Discharge Machining (EDM) process has the higher capability for cutting complex shapes with high precision, majorly for hard ceramic reinforced Aluminium Matrix Composites (AMCs). Hence, the EDM of AMCs is indispensable in many engineering applications; it is necessary to optimize EDM process parameters for machining AMCs. This research work focuses on optimization of EDM process parameters for Titanium Carbide (TiC) reinforced AA 6061 composite. For this study, the AA 6061/TiC composites are synthesised using stir casting technique with different weight percentage, i.e. 5, 10 and 15 wt. % of TiC reinforcement. The structural and elemental compositions of the fabricated AA6061/TiC composites are analyzed using X-Ray Diffraction (XRD) analyzer and Electron Dispersion Spectroscopy (EDS) respectively. The surface morphology of the AA6061/TiC composites are analysed using Optical Microscopy (OM), which revealed the arrangement of TiC particles are clear and uniform on the base matrix. The mechanical properties such as hardness, tensile strength, compressive strength and flexural strength of the AA6061/TiC composites are evaluated. The mechanical properties of AA6061/TiC composites increase with increasing the TiC content, which is because of the induction of higher strength TiC particles into the matrix alloy. The experimentation is using EDM for AA6061/TiC composites and the surface morphology of the machined samples is examined using the Scanning Electron Microscopy (SEM). newline