Characterization and optimization of abrasive water jet machining parameters of aluminium/silicon carbide composites

Abstract Due to the complexity of high temperature and cutting tool wear, most machined components are still facing problems in terms of harder functional fillers that reinforce aluminium matrix composites. Conversely, abrasive water jet machining (AWJM) incredibly useful for the cutting of anisotropic and non-homogeneous metal matrix composites. In this research article, silicon carbide (SiC) particulates were utilized as reinforcement in the AA6026 matrix material (AA6026/SiC) and machined using AWJM under different process parameters namely SiC loading, traverse speed and stand-off distance. Two different compositions of SiC (4, and 8 wt%) were considered to fabricate AA6026 composites using the stir casting. In addition, outputs have been examined, e.g., surface roughness, material removal rate, and kerf angle. An optical microscope, scanning electron microscope, Brinell hardness tester and universal testing machine have been used to characterize the matrix material AA6026 and its composites. Microstructural analysis revealed that the inclusion of SiC particulates in AA6026 affects the very fine grain size of the composite. Furthermore, the 8 wt% composite exhibits the evolution of the Al-Si eutectic phase during solidification. Processing of these composites was performed using the L 27 orthogonal geometry, successfully improving the parameters of the abrasive water jet process. The output response shows that reducing the SiC load improves the surface roughness under the key parameters of traverse speed and stand-off distance. However, increasing the SiC loading increases the material removal rate and kerf angle under the key parameters, namely traverse speed, and stand-off distance.