Electrical Discharge Machining of Al2024-65 vol% SiC Composites

doi:10.1007/s40195-016-0515-x

Acta Metallurgica Sinica (English Letters) ›› 2017, Vol. 30 ›› Issue (5): 447-455.DOI: 10.1007/s40195-016-0515-x

所属专题： 2017复合材料专辑

收稿日期:2016-08-23 修回日期:2016-09-20 出版日期:2017-05-20 发布日期:2017-05-23
作者简介:
作者简介冯立,男,1984年生,硕士,工程师

Electrical Discharge Machining of Al2024-65 vol% SiC Composites

Wen-Shu Yang¹(), Guo-Qin Chen¹(), Ping Wu², Murid Hussain³, Jia-Bing Song¹, Rong-Hua Dong⁴, Gao-Hui Wu¹()

1.Department of Materials Science and Engineering Harbin Institute of Technology Harbin China
2.Northwest Institute of Nuclear Technology Xi’an China
3.Department of Chemical Engineering COMSATS Institute of Information TechnologyLahorePakistan
4.Beijing Institute of Aerospace Control Devices Beijing China

Received:2016-08-23 Revised:2016-09-20 Online:2017-05-20 Published:2017-05-23
About author:
These authors contributed equally to this work.

摘要/Abstract

Abstract:

In the present work, the wire electrical discharge machining (WEDM) process of the 65 vol% SiCp/2024Al composite prepared by pressure infiltration methods has been investigated. The microstructure of the machined composite was characterized by scanning electron microscope, the average surface roughness (Ra), X-ray diffraction, X-ray photoelectron spectroscopy and transmission electron microscopy (TEM) techniques. Three zones from the surface to the interior (melting zone, heat affected zone and un-affected zone) were found in the machined composites, while the face of SiC particles on the surface toward the outside was “cut” to be flat. Increase in Al and Si but decrease in C and O were observed in the core areas of the removed particles. Si phase, which was generated due to the decomposition of SiC, was detected after the WEDM process. The irregular and spherical particles were further observed by TEM. Based on the microstructure observation, it is suggested that the machining mechanism of 65 vol% SiCp/2024Al composite was the combination of the melting of Al matrix and the decomposition of SiC particles.

Key words: Metal matrix composites, SiCp/Al composite, Metal infiltration, Wire electrical discharge machining (WEDM), SiC decomposition, Machining mechanism

. [J]. Acta Metallurgica Sinica (English Letters), 2017, 30(5): 447-455.

Wen-Shu Yang, Guo-Qin Chen, Ping Wu, Murid Hussain, Jia-Bing Song, Rong-Hua Dong, Gao-Hui Wu. Electrical Discharge Machining of Al2024-65 vol% SiC Composites[J]. Acta Metallurgica Sinica (English Letters), 2017, 30(5): 447-455.

图/表 12

Fig. 1 Representative SEM morphologies of SiC particles. a Low magnification, b high magnification

Table 1 Chemical composition of 2024Al matrix alloy (mass fraction, %)

Cu	Mg	Mn	Fe	Si	Zn	Cr	Ti	Ni	Al
4.79	1.49	0.611	0.245	0.168	0.068	0.049	0.046	0.013	Balance

Table 2 Basic properties of the 65 vol% SiCp/2024Al composite

Density (g/cm³)	Porosity (%)	Elastic modulus (GPa)	Hardness (HB)	Bending strength (MPa)	Electrical conductivity (IACS%)
2.99	1.6	167	265	622	18

Fig. 2 Representative surface morphologies of 65 vol% SiCp/2024Al composite after a polishing, b the WEDM process

Fig. 3 Representative roughness profiles of the 65 vol% SiCp/2024Al composite after the WEDM process

Fig. 4 Cross-sectional microstructure of 65 vol% SiCp/2024Al composite after the WEDM process: a SEM observation result, b corresponding schematic diagram

Fig. 5 Microstructure of the residual SiC particles on the surface after the WEDM process: a SEM observation, b magnification of red box area in a, c corresponding schematic diagram of b

Fig. 6 Representative morphology of the removed products of SiCp/2024Al composite after the WEDM process: a, b morphologies of different products, c-e corresponding EDS analysis of the red, blue box area in a and of the green box area in b, respectively

Fig. 7 Polished microstructure of the removed products of SiCp/2024Al composite after the WEDM process: a morphology, b, c corresponding EDS analysis of the red and blue box area in Fig. 2a, respectively

Fig. 8 Comparison of the XRD patterns of SiCp/2024Al composite and removed products after the WEDM process

Fig. 9 XPS analysis of the removed products of SiCp/2024Al composite after the WEDM process: a full spectrum, b narrow spectrum

Fig. 10 TEM and HRTEM observations of the removed products of SiCp/2024Al composite after the WEDM process: a irregular and b sphere products, c surface of irregular products, d corresponding SAED pattern of Si-O amorphous layer in c, e surface of sphere products, f corresponding SAED pattern of graphite layer in e

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Electrical Discharge Machining of Al2024-65 vol% SiC Composites

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