Machinability enhancement of stir cast Al-TiCp composites under cryogenic condition

The current research work makes an attempt to develop a methodology in order to produce high-quality Al-TiC_p composites by using systemized inert atmospheric stir casting facility. The quality of produced composites was characterized using microstructural, Energy-dispersive X-ray spectroscopy (EDX), and machinability studies. Atomized-Cryogenic-Liquid (ACL) spray machining technique was developed and used to enhance the machinability of composite. The results of microstructural analysis reveal that TiC_p refines Al grain structure to 50 times lesser than non-reinforced Al grains along the full length of the casting. Energy-dispersive X-ray analysis confirms that no metallic reaction takes place. Machining studies reveal that atomized cryogenic liquid-spray machining significantly improves the quality of machined surface and reduces the progressive wear occurring on tool during turning of Al-TiC_p composites in comparison with cryogenically chilled argon, wet, and dry machining conditions, respectively. The scientific methodology highlighted in this study helps to improve the productivity and reduces the manufacturing cost in various industrial applications.