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Synthesis, properties and EDM behavior of 10 wt.-% ZrB2 reinforced AA7178 matrix composites

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Published/Copyright: November 15, 2018
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Materials Testing
From the journal Materials Testing Volume 60 Issue 9

Abstract

The present study outlines the optimization of process parameters in the EDM of AA7178-10 wt.-% ZrB2 composites. The composites were fabricated by using stir casting and the mechanical properties are evaluated. The mechanical properties of AA7075, AA7178 and AA7178-10 wt.-% ZrB2 composites were reported. Scanning electron microscope (SEM) and energy dispersive spectrometry (EDS) analysis were used to characterize the composites. The fabricated composite material was machined using different process parameters based on Taguchi's L9 orthogonal array. Parameters such as current (I), pulse on time (PT-on) and pulse off time (PT-off) were varied. The response variables measured for the analysis are material removal rate (MRR) and surface roughness (SR). From the SN Ratio (SNR) analysis, it was observed that, current is the significant factor affecting both MRR and SR. ANOVA analysis was carried out to determine the percentage contribution of each factor to the responses. Further, a verification experiment was performed to confirm the performance of optimum parameters.

Kurzfassung

Der vorliegende Beitrag zeigt die Optimierung der Prozessparameter bei der Funkenerosion (EDM – Electrical Discharge Machining) von AA7178 Kompositen mit 10 wt.-% ZrB2. Die Komposite wurden mittels des Rührgießens hergestellt und ihre mechanischen Eigenschaften wurden bestimmt, wobei die Werte für die Legierungen AA7075 und AA7178 zum Vergleich ermittelt wurden. Um die Komposite zu charakterisieren wurden Rasterelektronenmikroskopie und EDS angewandt. Die hergestellten Komposite wurden mit verschiedenen Prozessparametern bearbeitet, und zwar basierend auf einem orthogalen Taguchi L9 Array. Hierbei wurden die Parameter Stromstärke I, Puls-An-Zeit und Puls-Aus-Zeit variiert. Die Antwortvariablen Materialabtragsrate und Oberflächenrauheit wurden zur Analyse gemessen. Aus der Signal-Rauschabstandsanalyse ergab sich, dass die Stromstärke ein signifikanter Einflussfaktor ist, die die Materialabtragsrate und auch die Oberflächenrauheit beeinflusst. Es wurde eine ANOVA-Analyse durchgeführt, um den prozentualen Beitrag eines jeden Faktors auf die entsprechenden Antworten zu kennen. Darüber hinaus wurden Experimente durchgeführt, um das Ergebnis mit den optimalen Parametern zu bestätigen.

Keywords: AA7178; composites; ZrB2; stir casting; Taguchi; EDM
*Correspondence Address, Assoc. Prof. Dr. M. Ravichandran, Department of Mechanical Engineering, K. Ramakrishnan College of Engineering, Samayapuram, Trichy, Tamil Nadu, India, E-mail:

Mr. S. Dineshkumar, BEng, MEng, born 1990, is presently working as an Assistant Professor in the Mechanical Engineering department of the Chendhuran College of Engineering and Technology, Pudukkottai, India. He obtained his BEng Degree in Mechanical Engineering and MEng degree in Manufacturing Engineering at Anna University, Chennai, India.

Dr. M. Ravichandran, B. E., M.Tech., Ph.D., born 1981, is Associate Professor of the Mechanical Engineering Department of the K. Ramakrishnan College of Engineering, Trichy, India. He obtained his BEng Degree in Mechanical Engineering at Bharathidasan University, Trichy, India, his MTech degree in Advanced Manufacturing from SASTRA University, Thanjavur, India and his PhD from Anna University, Chennai, India.

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Published Online: 2018-11-15
Published in Print: 2018-09-30

© 2018, Carl Hanser Verlag, München

Articles in the same Issue

  1. Inhalt/Contents
  2. Contents
  3. Fachbeiträge/Technical Contributions
  4. Compression testing of additively manufactured continuous carbon fiber-reinforced sandwich structures
  5. Microstructure and mechanical properties of nano-carbon reinforced Cu-based powder metallurgy friction materials produced by hot isostatic pressing
  6. Thermo-mechanical testing of TiO2 functional coatings using friction stir processing
  7. Ternary melt blend based on poly (lactic acid)/chitosan and cloisite 30B: A study of microstructural, thermo-mechanical and barrier properties
  8. Untersuchungen zur verlässlichen Messung der Härte nach dem UCI – Verfahren (Ultrasonic Contact Impedance)
  9. Electrochemical impedance spectroscopy of sand of varied particle size and water content using the three-electrode system
  10. Recycling of LM25 aluminum alloy scraps
  11. Mechanical fracture characterization of adhesive interfaces: Introducing a new concept for evaluating adhesive quality
  12. Effect of welding processes on mechanical and microstructural properties of S275 structural steel joints
  13. Essential Work of Fracture: Bestimmung des gültigen Ligamentbereiches mittels digitaler 3D-Bildkorrelation
  14. Synthesis, properties and EDM behavior of 10 wt.-% ZrB2 reinforced AA7178 matrix composites
  15. Solid particle erosion wear behavior of severe plastically deformed AA7075 alloys
  16. Performance of coated and uncoated carbide/cermet cutting tools during turning
  17. Assessment of soft materials for anthropomorphic soft robotic fingertips
  18. Application of the grey based Taguchi method and Deform-3D for optimizing multiple responses in turning of Inconel 718
https://doi.org/10.3139/120.111226
Keywords for this article
AA7178; composites; ZrB2; stir casting; Taguchi; EDM

Articles in the same Issue

  1. Inhalt/Contents
  2. Contents
  3. Fachbeiträge/Technical Contributions
  4. Compression testing of additively manufactured continuous carbon fiber-reinforced sandwich structures
  5. Microstructure and mechanical properties of nano-carbon reinforced Cu-based powder metallurgy friction materials produced by hot isostatic pressing
  6. Thermo-mechanical testing of TiO2 functional coatings using friction stir processing
  7. Ternary melt blend based on poly (lactic acid)/chitosan and cloisite 30B: A study of microstructural, thermo-mechanical and barrier properties
  8. Untersuchungen zur verlässlichen Messung der Härte nach dem UCI – Verfahren (Ultrasonic Contact Impedance)
  9. Electrochemical impedance spectroscopy of sand of varied particle size and water content using the three-electrode system
  10. Recycling of LM25 aluminum alloy scraps
  11. Mechanical fracture characterization of adhesive interfaces: Introducing a new concept for evaluating adhesive quality
  12. Effect of welding processes on mechanical and microstructural properties of S275 structural steel joints
  13. Essential Work of Fracture: Bestimmung des gültigen Ligamentbereiches mittels digitaler 3D-Bildkorrelation
  14. Synthesis, properties and EDM behavior of 10 wt.-% ZrB2 reinforced AA7178 matrix composites
  15. Solid particle erosion wear behavior of severe plastically deformed AA7075 alloys
  16. Performance of coated and uncoated carbide/cermet cutting tools during turning
  17. Assessment of soft materials for anthropomorphic soft robotic fingertips
  18. Application of the grey based Taguchi method and Deform-3D for optimizing multiple responses in turning of Inconel 718
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