Machining aspects of a high carbon Fe3Al alloy

Iron aluminide alloys containing both ferrous as well as non-ferrous (aluminum) components form unique materials from machining theory and practice point of view. While the cutting tool materials specifically required for their machining are not available, the mechanism of machining of such materials containing ferrous and non-ferrous components has not been adequately investigated. This paper deals with fundamental aspects of chip formation and tool-life in machining of an iron aluminide, Fe3Al alloy. Microstructural analysis of chips shows that the interaction of chip and tool in the secondary deformation zone, dependent upon the cutting speed mainly determines the mechanism of chip formation. Results of tool-life testing indicate that thermal softening of tool point combined with abrasion is the predominant tool failure mechanism.