Investigations on the wire edm of aa7075 zrb2 in situ composites

Abstract

The conventional aluminum alloys are progressively replaced by Metal Matrix Composites (MMCs) in many applications due to its high strength to weight ratio, low thermal expansion, good wear and corrosion resistance, etc. The MMCs have gained a charismatic attention in the present era due to its superior mechanical properties. The Aluminum based Metal Matrix Composites (AMCs) have been emerged to fabricate the lighter weight and higher performance components used in aircraft, aerospace, automobile, marine and chemical industries. AMCs are extensively produced by incorporating the ceramic particles like TiB2, SiC, B4C, Al2O3, Si3N4, ZrB2, etc. into the aluminum matrix. The mechanical and wear properties of those new AMCs have not been adequately investigated. newlineThe development of secondary processes like cutting, joining, forming and machining of those new AMCs are insufficient and hence the applications of those AMCs are limited. The machining of those AMCs reinforced with hard ceramic particles is a great challenge using conventional machining processes. Conventional machining of such AMCs causes to damage the work piece and significant tool wear owing to presence of abrasive reinforcement particles. Wire Electrical Discharge Machining (WEDM) is an emerging unconventional machining technique which is used for cutting the materials with complicated shapes and profiles irrespective of the hardness, brittleness, toughness and melting point. In WEDM process, there is no contact between the workpiece and wire electrode and hence the WEDM is free from mechanical stresses due to having no cutting force virtually. The weldability of AMCs is reduced due to presence of the hard ceramic particles. newline newline