Improvement in surface integrity of CuAl8Fe3 bronze via diamond burnishing

• Published in: International journal of advanced manufacturing technology Vol. 119; no. 9-10; pp. 5885 - 5902
• Main Authors: Duncheva, Galya V., Maximov, Jordan T., Anchev, Angel P., Dunchev, Vladimir P., Argirov, Yaroslav B., Ganev, Nikolaj, Drumeva, Desislava K.
• Format: Journal Article
• Language: English
• Published: London Springer London 01.04.2022; Springer Nature B.V
• Subjects: Aluminum bronzes; Axial stress; Bronze; Burnishing; CAE) and Design; Computer-Aided Engineering (CAD; Corrosion fatigue; Corrosion resistance; Corrosive wear; Diamond burnishing; Diamonds; Engineering; Fatigue strength; Genetic algorithms; Heat treatment; Industrial and Production Engineering; Integrity; Mechanical Engineering; Media Management; Microhardness; Multiple objective analysis; Optimization; Original Article; Regression analysis; Sorting algorithms; Surface layers; Surface treatment; Wear resistance; Surface integrity; Micro-hardness; Residual stresses; Diamond burnishing; Aluminum bronze; Roughness
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-022-08664-9

The single-phase CuAl8Fe3 aluminum bronzes possess good strength and resistance to fatigue as well as high corrosion and wear resistance. Since this alloy contains less than 8.5% aluminum, it cannot be heat treated. Therefore, improvements in surface integrity (SI) can only be achieved via mechanical surface treatment. This article investigates the influence of the basic diamond burnishing (DB) process, as well as additional factors, on the SI characteristics of CuAl8Fe3 bronze. Using experiments and regression analyses, a multi-objective optimization of the DB process has been accomplished via non-dominated sorting genetic algorithm (NSGA-II) and optimal values of the factors have been established. Using these factor values, the SI characteristics of diamond-burnished CuAl8Fe3 specimens have been quantified. The conclusion has been reached that the DB of CuAl8Fe3 bronze can be implemented as mixed burnishing, i.e., DB results in a favorable combination of the height and shape parameters for the surface texture, very low roughness (nearly mirror surfaces), large (in absolute value) residual hoop and axial stresses at depths greater than 0.8 mm, high surface micro-hardness and strongly expressed grain-refined microstructures at depths of up to 0.15 mm. These SI characteristics suggest a significant increase in fatigue strength and wear resistance of CuAl8Fe3 bronze finished via DB.