Metal particulate production by modulation-assisted machining

Continuous production of Al 6061-T6 particulate using modulation-assisted machining (MAM) is demonstrated. Superimposition of a controlled, low-frequency modulation in conventional machining causes chips to form as discrete particles. By adjusting the conditions, equiaxed, platelet and fiber-shaped particles having narrow size distributions can be produced. Large-strain deformation leads to microstructure refinement and enhanced hardness. The process is applicable to a wide range of alloys and appears to be intrinsically scalable for large-volume production.