Corrosion Resistance Improvement of 6061 Aluminum Alloy by 2D Ultrasonic Vibrations Assisted Turning

Corrosion is a limiting factor in the long-term use of workpieces, especially in aluminum alloys. One of the suitable solutions to enhance the corrosion resistance of machined workpieces is to improve the corrosion-related mechanical properties through the application of new machining methods such as ultrasonic-assisted turning. In this study, the effects of ultrasonic vibration direction (along feed, cutting speed and both feed and cutting speed directions) on the surface roughness, surface defects, microstructure and corrosion resistance of 6061 aluminum parts have been investigated experimentally. The results reveal the greater effectiveness of 2D ultrasonic vibrations compared to 1D vibrations and conventional turning processes, in term of improvements in surface roughness, surface defects, and corrosion rate. The lowest and highest corrosion rates were equal to 0.482 and 14.96 mpy corresponding to 2D and conventionally turned samples respectively.