Effects of Trace Elements on the Microstructural and Machinability Characteristics of Al–Si–Cu–Mg Castings

Abstract

This study was undertaken to emphasize the influence of Sn and Bi addition on the machinability of Sr-modified, grain-refined, and heat-treated Al–Si B319 and 396 alloys. Drilling and tapping tests were conducted to examine the cutting forces, tool life, tool wear, built-up edge evolution, and chip shape. Microstructures were examined using optical and electron microscopy. Drilling test results show that the B319.2 alloy with 0.15%Sn yields the longest drill life, i.e., twice that of the B319.2 alloy containing 0.5%Bi, and one-and-a-half times that of the B319.2 alloy containing 0.15%Sn + 0.5%Bi. The presence of 0.5%Bi in the B319.2 alloy causes a deterioration of drill life (cf., 1101 holes with 2100 holes drilled in the B319.2 alloy containing 0.15%Sn). The α-Fe phase in the 396 alloy produces the highest number of holes drilled compared with alloys containing sludge or β-Fe. The presence of sludge decreases the drill life by 50%. Built-up edge (BUE) measurements and optical photographs show little change in the BUE width for different numbers of holes except for the B319.2 alloy containing 0.5%Bi, which shows a slightly lower width (0.166 mm) compared with that containing 0.15% Sn (0.184 mm) or 0.15%Sn + 0.5%Bi (0.170 mm).