Restricted accessResearch articleFirst published online 2025
Characterization of microstructure,mechanical properties and machinability of stellite-6 hard-faced cutting tool for machining high-strength aluminum alloys
The current study aims to develop a hard-faced cutting tool using an overlaying stellite-6 weld layer over the AISI 4140 steel. This research also aims to optimize the machining parameters for improved surface finish, material removal rate, and reduced tool wear. Manual metal arc welding was employed to hard-face the stellite-6 over the AISI4140 steel. The electron-backscattered diffraction and energy dispersive spectroscopy confirm the formation of a strong interface. Also, the energy dispersive spectroscopy results confirm the limited elemental migration and mixing observed at the interface, however it causes the intermediate hardness in the interface region. The hard-facing of stellite-6 over the AISI 4140 steel improves the hardness of the developed tool, and the hardness at the interface was 309 ± 4 HV. Taguchi L27 orthogonal array experiments conducted during the machining of AA7075 alloy identified optimal machining parameters as a spindle speed of 715 RPM, a feed rate of 0.32 mm/rev, and a depth of cut of 1.5 mm. These findings demonstrate the potential of the developed cutting tool for machining AA7075 alloy, particularly in the manufacturing of automotive and aerospace components.
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