Energy consumption model for the pipe threading process using 10 wt.-% Cu and 316L stainless steel powder-reinforced aluminum 6061 fittings

Abstract

Fitting products of different dimensions and design geometries are used in natural gas pipelines, water supply systems, fire installations, machinery equipment and in the aviation and automotive industries. This study aims to investigate the machinability of Al 6061-T6 fittings, which are widely used in the aerospace and automotive industries. In an endeavor to produce reliable and healthy installation systems, Al 6061 material was reinforced with 10 % copper and 316L stainless steel powder in order to increase its corrosion resistance and improve its mechanical properties for sustainable production. These new materials were threaded using a 1/2 BSP (British Standard Pipe) tap tool via the Taguchi L-9 method. Different materials, heat treatments and spindle speeds were used during this manufacturing process. The effects of these manufacturing parameters on the total power dissipated P-total were calculated using variance analysis (ANOVA). According to these results, the most effective parameter was the heat treatment type (44.9 %), followed by the material type (30.6 %) and the rpm (19.9 %). It was observed that these aluminum materials can be threaded using 30 to 40 % lower energy consumption compared to cast iron. In addition, the aluminum alloy fitting materials achieved higher hardness than the cast iron fittings.