Investigation on the Cutting Process of Plasma Sprayed Iron Base Alloys

Abstract

In the recent years, the current technology enables only the molten iron base alloys, sprayed on the aluminum alloy engine block thus it can function as a cylinder bore. However, the machinability performance of plasma spray coated cylinder bore in boring process is poor because of severe tool wear compared with the previous cast iron cylinder bore. This paper deals with the results obtained at boring process of plasma sprayed iron base alloys coating to clarify the root cause of tool wear. Preliminary fine boring and turning experiments are conducted on the plasma sprayed cylinder bore, and tool wear, tool failure modes and cutting force were also investigated. The result shows plasma spray coated cylinder bore recorded larger cutting force than the cast iron cylinder bore. Also, this work shows that abrasive effect by the hard oxide particles on the cross-sectioned of machined layer is superior when fine boring plasma spraying iron base alloys coating.