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<p>This study aims to comparatively investigate the structural, mechanical and drilling performances of as-cast AlSi10Mg and AlSi10MgCu alloys manufactured by gravity casting method. The alloys were subjected to microstructure, hardness, tensile and drilling. Microstructural analyses showed that Cu addition caused spheroidization of eutectic Si particles, formation of precipitate phases such as θ-Al₂Cu and Al₅Mg₈Cu₂Si₆ and increased heterogeneity in the matrix structure. According to the mechanical test results, the addition of Cu increased hardness by 6.67%, yield strength by 6.25%, and tensile strength by 20%, while elongation to fracture decreased by 14.28%. Drilling tests revealed that the lowest thrust force (Fz = 72.13 N) and torque (Mz = 32.70 Ncm) were obtained at cutting speed <i>(V)</i> = 155&#xa0;m/min and feed (<i>f</i>) = 0.04&#xa0;mm/rev. Furthermore, chip morphology and tool-tip observations indicated that Cu addition reduced built-up edge (BUE) formation and enhanced chip breakability, improving machinability. The Response Surface Methodology (RSM) models exhibited high reliability with R<sup>2</sup> values above 97%, and Analysis of Variance (ANOVA) confirmed the significant influence of feed rate on both responses. The obtained data provide important insights for optimizing machining parameters and understanding the positive influence of Cu addition on machinability.</p>

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Integrated Microstructural, Mechanical and Machinability Assessment of AlSi10Mg and AlSi10MgCu Alloys: Experimental and RSM-Based Optimization Approach

  • 期刊论文

  • 发表日期：

    2025年12月9日

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  • Cem Alparslan,
  • Yusuf Talha Can,
  • Uğur Dervişoğlu,
  • Ademcan Altıntaş,
  • Şenol Bayraktar

摘要

This study aims to comparatively investigate the structural, mechanical and drilling performances of as-cast AlSi10Mg and AlSi10MgCu alloys manufactured by gravity casting method. The alloys were subjected to microstructure, hardness, tensile and drilling. Microstructural analyses showed that Cu addition caused spheroidization of eutectic Si particles, formation of precipitate phases such as θ-Al₂Cu and Al₅Mg₈Cu₂Si₆ and increased heterogeneity in the matrix structure. According to the mechanical test results, the addition of Cu increased hardness by 6.67%, yield strength by 6.25%, and tensile strength by 20%, while elongation to fracture decreased by 14.28%. Drilling tests revealed that the lowest thrust force (Fz = 72.13 N) and torque (Mz = 32.70 Ncm) were obtained at cutting speed (V) = 155 m/min and feed (f) = 0.04 mm/rev. Furthermore, chip morphology and tool-tip observations indicated that Cu addition reduced built-up edge (BUE) formation and enhanced chip breakability, improving machinability. The Response Surface Methodology (RSM) models exhibited high reliability with R2 values above 97%, and Analysis of Variance (ANOVA) confirmed the significant influence of feed rate on both responses. The obtained data provide important insights for optimizing machining parameters and understanding the positive influence of Cu addition on machinability.