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<p>This study focuses on optimizing the surface roughness of SiC reinforced Al7039/Cu metal matrix composites (MMCs), crucial for high-precision and durable applications. Using a central composite design (CCD) and response surface methodology (RSM), the research addresses machining challenges posed by MMCs’ abrasive reinforcements and heterogeneous microstructure that typically impair tool performance and surface finish. The authors varied the weight fractions of Al7039, Cu, and SiC in 20 experimental trials, testing compositions of Al7039 (73–91wt. %), Cu (4–12wt. %), and SiC (5–15wt. %). Machining was performed on a Fanuc Series Oi-TF CNC precision lathe, focusing on both rough and finish turning operations to minimize reinforcement particle pullout and optimize surface finish. Surface roughness was quantitatively evaluated using a JB-4C precision roughness meter, and microstructural analysis was conducted on polished and etched specimens under inverted metallurgical microscopy. The study revealed significant effects of compositional variations on surface roughness, with a robust quadratic model (95% confidence) identifying an optimal alloy composition of 91.7% Al7039, 7.2% Cu, and 5% SiC. This composition achieved a predicted average surface roughness of 2.373 µm, closely matching the experimental value of 2.411 µm. These results demonstrate the effectiveness of mechanical and magnetic stirring techniques in promoting homogeneous dispersion of SiC particles and Cu, enhancing both microstructure and machining outcomes. The optimized MMC formulation not only achieves superior surface quality but also opens avenues for further improvements through advanced polishing techniques, making it suitable for demanding industries like aerospace, automotive, and mold tooling.</p>

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Effect of compositions weight fraction on surface roughness of Al7039/Cu/SiC MMCs: a central composite design approach

  • 期刊论文

  • 发表日期：

    2025年6月4日

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  • Fetene Teshome Teferi,
  • Kishor Purushottam Kolhe,
  • Assefa Asmare Tsegaw

摘要

This study focuses on optimizing the surface roughness of SiC reinforced Al7039/Cu metal matrix composites (MMCs), crucial for high-precision and durable applications. Using a central composite design (CCD) and response surface methodology (RSM), the research addresses machining challenges posed by MMCs’ abrasive reinforcements and heterogeneous microstructure that typically impair tool performance and surface finish. The authors varied the weight fractions of Al7039, Cu, and SiC in 20 experimental trials, testing compositions of Al7039 (73–91wt. %), Cu (4–12wt. %), and SiC (5–15wt. %). Machining was performed on a Fanuc Series Oi-TF CNC precision lathe, focusing on both rough and finish turning operations to minimize reinforcement particle pullout and optimize surface finish. Surface roughness was quantitatively evaluated using a JB-4C precision roughness meter, and microstructural analysis was conducted on polished and etched specimens under inverted metallurgical microscopy. The study revealed significant effects of compositional variations on surface roughness, with a robust quadratic model (95% confidence) identifying an optimal alloy composition of 91.7% Al7039, 7.2% Cu, and 5% SiC. This composition achieved a predicted average surface roughness of 2.373 µm, closely matching the experimental value of 2.411 µm. These results demonstrate the effectiveness of mechanical and magnetic stirring techniques in promoting homogeneous dispersion of SiC particles and Cu, enhancing both microstructure and machining outcomes. The optimized MMC formulation not only achieves superior surface quality but also opens avenues for further improvements through advanced polishing techniques, making it suitable for demanding industries like aerospace, automotive, and mold tooling.