Preparation of Alumina Fiber-Reinforced Aluminum by Squeeze Casting and Their Machinability

Alumina fiber-reinforced aluminum alloy composites were prepared by squeeze casting, and the effect of the reinforcement on the machinability of the alloy was investigated. Two kinds of short alumina fibers, which have the same fiber size but different hardness, were used. Preform in which the fibers were in a random arrangement was formed with SiO2 binder, and then was infiltrated with the alloy melt to prepare the composite. The fiber-matrix interfacial bond via the binder is sufficient and no reaction product was detected. The cutting force of the alloy was reduced by the fiber-reinforcement. The lower the hardness of the fiber in the composite, the lower the cutting force of the composite. The roughness of the machined surface was drastically decreased by the reinforcement. Observation of the chip formed on the machined surface indicated that the fiber suppressed the formation of the built-up-edge, and this fact would lead to the reduction in the surface roughness by the reinforcement. The chips were shortened by the reinforcement. The difference in hardness of the alumina fiber hardly affected the roughness and the chip morphology. The hardness of the fiber has a strong effect to decrease the tool life.