The objective of this paper was to determine the optimum process parameters of an electric discharge machine while machining a new hybrid aluminum metal matrix composite. In this study, a new hybrid aluminum metal matrix composite was prepared, with silicon carbide and graphite particles used as reinforcements, with the help of the stir casting method. The selected electric discharge machining parameters in this study were peak current (I), voltage (V), pulse-on time (T_on), and tool material, while the response parameters were material removal rate and surface roughness. To machine the fabricated samples, two different types of tool materials (copper and brass) were used as electric discharge machine electrodes, and each had a diameter (Ø) of 12.0 mm. The optimal settings of the electric discharge machining parameters were determined through experiments planned, conducted, and analyzed using the Taguchi (L₁₈) technique. An analysis of variance and confirmatory tests were used to check the contribution of each machining parameter. It was found that the material removal rate increased with the increase in pulse-on time and pulse current, whereas the material removal rate decreased with the increase in voltage. On the other hand, reduced surface roughness could only be achieved when current, voltage, and pulse duration were low. It was also found that the selected electric discharge machining electrodes had a significant effect on both the material removal rate and the surface roughness.

Due to their superior capabilities for manufacturing lightweight automotive components, aluminium metal matrix composites have gained a lot of attention in the last few years. Aluminium metal matrix composites are an exceptional class of metal matrix composites that can solve all the major problems related to the automobile industry. Aluminium matrix composites in the disc braking system have already been employed and studied by many scientists. However, the developed materials are not yet always sufficiently accurate and reliable. In this article, a new enhanced metal matrix composite material is used and studied to improve the efficiency of an ordinary car’s braking system. To improve the accuracy of the designated braking system, an innovative hybrid aluminium matrix composite (Al6061/SiC/Gr)-based brake rotor has been developed, and its effectiveness has been determined by finite element analysis. From the simulation, the product performance confirmed that the hybrid aluminium matrix composite (Al6061/SiC/Gr)-based brake rotor has the potential to replace the standard cast iron brake disc. The new enhanced hybrid composite material used in this study can be used for the efficient design of various braking parts.

In this study, different input parameters for electric discharge machining (EDM) are examined in order to revise the distinctiveness of EDM for machining aluminum-based hybrid metal matrix composites (MMCs). The versatility of hybrid aluminum MMCs makes them very popular and sought after in the automotive, aerospace, marine, and space industries. In this article, an optimized process parameter setting for hybrid MCCs machining with an EDM machine is determined that have silicon carbide (SiC_p) and graphite (Gr_p) particles added as reinforcement materials in varying amounts (Al–0.7Fe–0.6Si–0.375Cr–0.25Zn/10 wt%SiC/3 wt%Gr–MMC, Al–0.7Fe–0.6Si–0.375Cr–0.25Zn/15 wt%SiC/5 wt%Gr–MMC, and Al–0.7Fe–0.6Si–0.373Cr–0.25Zn/20 wt%SiC/8 wt%Gr–MMC). The stir casting method was used to prepare these hybrid aluminum MMCs (3 samples). A study of surface roughness (SR) and material removal rate (MRR) was conducted to examine the effects of dominant parameters. An experiment is planned using a central composite rotatable design (CCRD) of response surface methodology (RSM). It is possible to predict MRR and SR with 95% degree of accuracy by utilizing the quadratic model. Non-dominating Sorting Genetic Algorithm-II was employed to solve “mathematical models” for multi-objective optimization of output response characteristics. The scanning electron microscope (SEM) images of the tool and workpiece materials show that the recast layer has been formed on the tool face and the surface of the machined work-piece. Based on the results, it was determined that an optimal value of MRR (2.97 g·min⁻¹) was obtained at 90 µs, 30 µs, 7.0 V, and 14 A asP_on,P_off, gap voltage, and peak current, respectively. As a result of the findings, the SR is reciprocally proportional toP_on, and the SR is commensurate withP_off. It was determined that the optimal value of SR (2.41 µm) could be attained at 30 µs, 52 µs, 6.0 V, and 12 A as theP_on,P_off, gap voltage, and peak current, respectively. For an optimal set of response variables,P_oncan be specified as 30 µs,P_offas 30 µs, gap voltage as 6 V, and peak current as 14 A as process parameters for MRR and SR. The SEM images of the tool material and the workpiece material clearly demonstrate a recast layer formed on the tool face and the machined surface of the workpiece. The optical microscopy analysis reveals a uniform distribution of SiC_pand Gr_pparticles in the Al–0.7Fe–0.6Si–0.375Cr–0.25Zn matrix. In addition to recast layers and machined surfaces, EDS analysis reveals the deposition of tool material on the surface of the workpiece. The composites fabricated may replace materials in many of these applications where “friction” is a significant factor.

Friction stir spot welding (FSSW) is one of the most popular fusion joining processes. The process is a solid-state welding process that allows welding of weldable as well as non-weldable materials. As a part of this investigation, weld samples of Al6061-T6 were reinforced with silicon carbide (SiC) powder with an average particle size of 45 µm. Initially, a Taguchi L9 orthogonal array was developed with three factors, i.e., rotational speed of the tool, pre-dwelling time, and diameter of the hole that was filled with SiC before welding. The effects of the SiC particles and process parameters were investigated as tensile–shear load and micro-hardness. The optimisation of parameters in order to maximise the output responses—i.e., strength and hardness of the welded joints—was performed using a hybrid WASPAS–Taguchi method. The optimised process parameters obtained were a 3.5 mm guiding hole diameter, 1700 rpm tool rotation speed, and 14 s of pre-dwelling time.

Harish Kumar Garg was not included as an author in the published article