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Article

Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys

1
École de Technologie Supérieure, Département de Génie Mécanique, Montréal, QC H3C 1K3, Canada
2
Département des Sciences Appliquées, Université du Québec à Chicoutimi, Chicoutimi, QC G7H 2B1, Canada
3
Department of Metallurgical Engineering Program, Cairo University, Cairo 12613, Egypt
4
General Motors Global Technology Center, Warren, MI 48093-2350, USA
*
Author to whom correspondence should be addressed.
Academic Editor: Antonio Riveiro
Materials 2022, 15(3), 916; https://doi.org/10.3390/ma15030916
Received: 6 January 2022 / Revised: 21 January 2022 / Accepted: 21 January 2022 / Published: 25 January 2022
(This article belongs to the Topic Metallurgical and Materials Engineering)
The present study was conducted on the machinability of 396 alloy (containing approximately 11% Si) and B319.2 alloy mainly to emphasize the effects of Fe-intermetallics, i.e., α-Fe, β-Fe, and sludge. The results demonstrate that the presence of sludge in the form of hard spots has a significant effect on cutting forces and tool life, in that it decreases drill life by 50% compared to the base alloy. The formation of the α-Fe phase in the M1 base alloy has a beneficial effect on tool life in that this alloy produces the highest number of holes drilled compared to alloys containing sludge or β-Fe; this result may be explained by the fact that the formation of the α-Fe intermetallic, with its rounded Chinese script morphology and its presence within α-Al dendrites, is expected to improve matrix homogeneity via hardening of the soft α-Al dendrites. Increasing the Fe-content from 0.5% to 1% in the 396-T6 alloy containing 0.5% Mn produces a distinct improvement in alloy machinability in terms of cutting force and tool life. The addition of Fe and/or Mn appears to have no discernible effect on the build-up edge area (BUE) and chip shape. View Full-Text
Keywords: drilling; cutting forces; cutting moments; intermetallics; free cutting elements; tool life drilling; cutting forces; cutting moments; intermetallics; free cutting elements; tool life
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MDPI and ACS Style

Zedan, Y.; Garza-Elizondo, G.H.; Tash, M.; Samuel, A.M.; Doty, H.W.; Songmene, V.; Samuel, F.H. Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys. Materials 2022, 15, 916. https://doi.org/10.3390/ma15030916

AMA Style

Zedan Y, Garza-Elizondo GH, Tash M, Samuel AM, Doty HW, Songmene V, Samuel FH. Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys. Materials. 2022; 15(3):916. https://doi.org/10.3390/ma15030916

Chicago/Turabian Style

Zedan, Yasser, Guillermo H. Garza-Elizondo, Mahmoud Tash, Agnes M. Samuel, Herbert W. Doty, Victor Songmene, and Fawzy Hosny Samuel. 2022. "Effect of Intermetallics and Drill Materials on the Machinability of Al-Si Cast Alloys" Materials 15, no. 3: 916. https://doi.org/10.3390/ma15030916

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