Morphology of 6061-T6 Aluminum Surfaces Generated by Steel Wire Brushing

Abstract

In this thesis, the characteristic surface which is generated during orthogonal wire brushing of a flat 6061-T6 aluminum workpart is examined. Scanning electron microscopy is used for characterization of surface structure, whereas subsurface microstructure and properties of the brushed region and filament tips from the brush are evaluated by metallographically examining through-thickness cross-sections and performing microhardness measurements, respectively. Unique topographical characteristics of the contact zone and filament tips are reported which suggest material removal and subsequent redeposition onto the workpart surface. On the basis of information generated during the investigation, a qualitative theory is postulated which identifies transfer mechanisms for removal and redeposition of aluminum alloy