Study of Microstructural and Machining Characteristics of Hypereutectic Al-Si Alloys Using Wire-EDM for Photovoltaic App
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ORIGINAL PAPER
Study of Microstructural and Machining Characteristics of Hypereutectic Al-Si Alloys Using Wire-EDM for Photovoltaic Application Priyaranjan Samal 1
&
D. Mani Babu 1 & S. Venkat Kiran 1 & B. Surekha 2 & Pandu R. Vundavilli 1 & Animesh Mandal 3
Received: 29 April 2020 / Accepted: 28 September 2020 # Springer Nature B.V. 2020
Abstract Aluminum-Silicon (Al-Si) alloys are extensively used in aerospace, automotive, thermal storage, and other engineering sectors because of their enhanced mechanical properties. Recently, Al-Si alloys are proved to be an efficient material for thermal storage during high and medium temperature storage applications. Hypereutectic Al-Si alloys are proved to be promising alloys due to their low coefficient of thermal expansion, low density, high wear, and corrosion resistance. In the present manuscript, an attempt is made to study the microstructural and machining characteristics of Al-Si alloys with a varying percentage of Silicon (16%, 20%, and 24%) in the alloy systems. Microstructural analysis was carried out on both the as-cast and heat-treated conditions through FESEM analysis. Further, the machinability studies of the alloy systems are studied by machining them using wire electric discharge machining (WEDM). It was observed that as cast Al-Si alloy has shown better machining characteristics than that of the heat-treated alloy. With the enhanced machining properties, the Al-Si alloy is well suited for the fabrication of structural parts of photovoltaic solar cells. Keywords Hypereutectic Al-Si alloys . Microstructure . Machinability . Wire electric discharge machining . Material removal rate
1 Introduction Aluminum-silicon alloy systems are the most versatile and commonly used alloy systems for producing light metal casting because of their low weight and excellent mechanical properties at elevated temperature, castability, good machinability, and economical, which makes them suitable for many engine components [1]. The counter electrodes [2] used in the solar cells were also produced using these Al-Si alloys. Recently, researchers are motivated to focus on the study of unmodified hypereutectic Al-Si alloys. It is interesting to note that silicon, as an alloying element, principally improves the
* Priyaranjan Samal [email protected] 1
School of Mechanical Sciences, Indian Institute of Technology Bhubaneswar, Bhubaneswar 752050, India
2
School of Mechanical Engineering, KIIT University, Bhubaneswar 751024, India
3
School of Minerals, Metallurgical and Materials Engineering, Indian Institute of Technology Bhubaneswar, Bhubaneswar 752050, India
castability i.e. readiness in filling the dies and helps in solidifying the casting without any hot cracking or hot tearing issues. Moreover, with higher silicon content, the thermal expansion coefficient of the alloy was found to be reduced. The alloy had exhibit significantly higher wear resistance because of its hard nature. Moreover, the mechanical behavior of Al-Si alloys was mostly affected by the morphology of the
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