Al-Mg-MoS₂ Reinforced Metal Matrix Composites: Machinability Characteristics

Area of Science:

• Materials Science and Engineering
• Manufacturing Processes

Background:

• Aluminum-Magnesium (Al-Mg)-based composites are crucial for various components.
• Molybdenum disulfide (MoS2) is incorporated to enhance machinability.
• Understanding the machinability of reinforced composites is vital for industrial applications.

Purpose of the Study:

• To explore the machinability properties of Al-Mg composites reinforced with varying weight percentages of MoS2 (3%, 4%, and 5%).
• To investigate the impact of WEDM process parameters on surface roughness and overcut.
• To determine the optimal WEDM settings for desired surface finish and minimal overcut using the EDAS method.

Main Methods:

• Fabrication of Al-Mg-MoS2 composites with 3%, 4%, and 5% MoS2 reinforcement.
• Wire Electrical Discharge Machining (WEDM) was employed to machine the composites.
• Evaluation-based Distance from Average Solution (EDAS) method was utilized for multi-criteria decision-making to find optimal parameters.

Main Results:

• Surface roughness and overcut generally increased with higher MoS2 reinforcement levels.
• WEDM process parameters, specifically peak current and pulse on-time, significantly influenced surface roughness and overcut.
• The optimal WEDM conditions (I3, Ton2, V1) identified by EDAS were consistent across all tested composite compositions.

Conclusions:

• The addition of MoS2 to Al-Mg composites affects their machinability characteristics.
• Optimal WEDM parameters can be determined using the EDAS method for achieving desired surface quality.
• Peak current and pulse on-time are critical factors in controlling surface roughness and overcut during WEDM of these composites.