Effects of Fe intermetallics on the machinability of heat-treated Al–(7–11)% Si alloys

Abstract The need for bridging the divide between the casting process and the machining process provides a strong motivation for examining the various aspects affecting the machinability of Al–Si casting alloys, given that these alloys constitute about 85% of all aluminum castings produced. Strontium-modified, grain-refined, T6 heat-treated 396 alloys (containing ∼11% Si), and B319.2 and A356.2 alloys (containing ∼7% Si) were selected, with a view to studying their machinability characteristics. Three 396 alloy compositions were selected (M1, M3, M4) such that different iron intermetallic phases were obtained in each case. Drilling and tapping operations were both carried out using a Makino A88E machine under fixed machining conditions. The machinability criteria relates to forces and moment analysis as well as to tool life, chip configuration, and built-up edge (BUE) evolution. The effects of Fe-intermetallics (α-Fe, β-Fe, and sludge) on the machining characteristics of these alloys were investigated and a comparison was made between the three 396 alloys in terms of mean total drilling forces, mean total tapping forces, tool life, and chip configuration. The results demonstrate that the presence of sludge has a significant effect on cutting forces and tool life. The tool life of the 396-M3 alloy (containing sludge) decreased by 50% compared to the base alloy 396-M1 (containing α-Fe intermetallics). Increasing the Fe-content from 0.5% to 1% in the M1 alloy (i.e., M4 alloy) produces a distinct improvement in the alloy machinability in terms of cutting forces and tool life. The addition of Fe and Mn appears to have no discernible effect on the built-up-edge (BUE) width and chip configuration as compared to the base alloy. The dominant type of wear which leads to drill failure and breakage is outer corner wear; there is, however, no evidence of crater-wear. Fan-shaped chips were obtained during machining of the 396, B319.2 and A356.2 alloys, where the latter alloy yielded the largest chips. As far as the alloy Si content was concerned, it was found that the 396 alloys produce drilling results similar to those of the B319.2 and A356.2 alloys, in terms of the number of holes drilled (cf. 2160 with 2100 and 2285 holes drilled in the B319.2, and A356.2 alloys, respectively). During tapping tests, however, the B319.2 alloy yielded the longest tool life, i.e., more than twice that of 396 alloy and four-and-half-times that of the A356.2 alloy.