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<p>Friction drilling, or thermal drilling, is a non-conventional method used to create holes with bushings in thin-walled materials by applying axial pressure and heat generated through friction between the tool and the workpiece. Although widely employed in automotive and aerospace industries, thermal drilling is less commonly applied to brittle metals, especially as-cast A356 aluminum alloy, due to the tendency for bushings to develop cracks, radial fractures, and petal formations. This study investigates the effects of preheating on the characteristics of friction-drilled as-cast A356 aluminum alloy, specifically examining how preheating influences defect formation at various rotational speeds (2000–4000&#xa0;rpm) and feed rates (40–80&#xa0;mm/min). Preheating was conducted at 100&#xa0;°C, 150&#xa0;°C, and 200&#xa0;°C to improve material deformation during the drilling process. The results highlight the evolution of petal formation, bushing dimensions, surface roughness, and hardness in both room temperature and preheated conditions. The results showed that cracking was mitigated in the preheated conditions processed at a rotational speed of 4000&#xa0;rpm and a feed rate of 40&#xa0;mm/min. However, bushing thicknesses were decreased in the preheated conditions, for example the average thickness of the friction drilled specimens without preheating recorded an average of 2.2 ± 0.2&#xa0;mm, whereas the average thickness of the preheated specimens was 1.7 ± 0.2&#xa0;mm. Furthermore, the surface roughness deteriorated with a preheating temperature rise. In addition, hardness values were increased near the edge of the drilled bushing (stirring zone, SZ) as compared to the base metal due to formations of very fine structures resulting from the severe plastic deformation in the SZ.</p>

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Impact of preheating on the friction drilling characteristics of A356 aluminum alloy

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年1月3日

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  • Mahmoud Khedr,
  • Ahmed Abdelkareem,
  • Tamer S. Mahmoud,
  • Rasha Afify

摘要

Friction drilling, or thermal drilling, is a non-conventional method used to create holes with bushings in thin-walled materials by applying axial pressure and heat generated through friction between the tool and the workpiece. Although widely employed in automotive and aerospace industries, thermal drilling is less commonly applied to brittle metals, especially as-cast A356 aluminum alloy, due to the tendency for bushings to develop cracks, radial fractures, and petal formations. This study investigates the effects of preheating on the characteristics of friction-drilled as-cast A356 aluminum alloy, specifically examining how preheating influences defect formation at various rotational speeds (2000–4000 rpm) and feed rates (40–80 mm/min). Preheating was conducted at 100 °C, 150 °C, and 200 °C to improve material deformation during the drilling process. The results highlight the evolution of petal formation, bushing dimensions, surface roughness, and hardness in both room temperature and preheated conditions. The results showed that cracking was mitigated in the preheated conditions processed at a rotational speed of 4000 rpm and a feed rate of 40 mm/min. However, bushing thicknesses were decreased in the preheated conditions, for example the average thickness of the friction drilled specimens without preheating recorded an average of 2.2 ± 0.2 mm, whereas the average thickness of the preheated specimens was 1.7 ± 0.2 mm. Furthermore, the surface roughness deteriorated with a preheating temperature rise. In addition, hardness values were increased near the edge of the drilled bushing (stirring zone, SZ) as compared to the base metal due to formations of very fine structures resulting from the severe plastic deformation in the SZ.