Performance analysis on mechanical and machinability attributes of Al6061-B₄C-T6 composites processed via hot extrusion

Abstract

In this study, composite materials with Al6061 alloy matrix and B4C particles reinforcement were produced by hot extrusion process. Fabricated composites were examined for the mechanical and machinability attributes. Al6061 alloy powders (<100 µm) and B4C particles (<10 µm) were mixed with the different weight fraction of B4C (3%, 6%, and 9% by weight) of and then cold pressed under 200 MPa pressure. The cold pressed powder metal block was extruded hot after preheating at 550°C for 1 h. Further, the composites were subjected to T6 aging heat treatment after hot extrusion. Microstructure, density, hardness, tensile strength, and wear properties were examined. The effects of cutting speed and cutting force on the machinability were also investigated. In addition, surface roughness and chips formation were examined. High density (99.6%) values were achieved with the extrusion process. With increasing B4C particles ratio, the hardness and tensile values were increased which was substantiated by the fracture morphology of the tensile specimens. It has been observed that tool smearing was high in the machining of the low-reinforced (3% B4C) composite. The highest cutting force was measured as 236 N at a feed rate of 0.27 mm/rev and a cutting speed of 250 m/min. It has also been observed that the average surface roughness decreased with increasing cutting speed and it increased with increasing feed rate.