Analysis of interfacial failure and particle damage of SiCp/Al with ultrasonic vibration-assisted cutting

Aluminum-based silicon carbide composite materials have a wide range of applications in highend equipment manufacturing, but there are problems with processing difficulties and poor surface quality. Reducing particle damage is crucial for improving surface quality, and interfacial failure between silicon carbide particles and aluminum matrix is a prerequisite for particle damage, however, the mechanism of interfacial failure on particle damage is not perfect. In this study, based on the different degrees of interfacial damage during the cutting process, three new conceptual models of different interfacial failure forms are proposed to visualize the influence of interfacial failure on particle damage. By observing the surface and subsurface microstructure of the material after machining and comparing the effects of conventional and ultrasonic vibrationassisted turning on the interface, it is found that the Dislocation pile-up due to stress concentration is the key factor of interface damage. Combining experiments and simulations, ultrasonic vibration-assisted turning reduces the occurrence of dislocation pile-up and dislocation kinks at the interface, which reduces the particle damage caused by interfacial failure. The experimental results show that crack extension is inhibited, surface scratches and pits are reduced, and surface roughness is reduced by 32%. This can effectively improve the material's service life and corrosion resistance. The experimental parameters provide experimental reference and theoretical guidance for industrial processing.