INFLUENCES OF P AND Sr ON MICROSTRUCTURE AND ITS EFFECTS ON MACHINABILITY AND MECHANICAL PROPERTIES OF HYPEREUTECTIC Al-20%Si

Hypereutectic Al-Si alloys are widely utilized in the automotive industry due to their high strength-to-weight ratio, minimal thermal expansion, and superior castability. The downside of hypereutectic Al-Si alloys is the formation of coarse primary silicon particles. The primary Si phases were controlled by the growth-hindering agents, phosphorus (refiner), and strontium (modifier) by using a conventional stir casting technique at room temperature. The microstructural changes were observed through an optical microscope and SEM analysis. The additions of 0.08% P have ensured the formation of the uniformly distributed fine-grained particles in the alloy. The primary silicon particle size was reduced from 220[Formula: see text][Formula: see text]m to 150[Formula: see text][Formula: see text]m as compared to the untreated alloy. The tensile and yield properties of the treated alloy were increased by 12.7% when compared to the untreated alloy with a hardness of 131 BHN. The treated alloy imparted better impact toughness, ensuring a ductile mode of failure through the fractography studies. The influence of the microstructure on the machinability of the alloy was investigated in a dry environment with uncoated and coated inserts (code: CCGT 09T304 FL K10) by varying the process parameters, i.e. speed, feed rate, and depth of cut (DoC). Modification of the primary and eutectic Si phases of an Al-20Si hypereutectic alloy increases machinability with coated inserts as well as its mechanical properties.