Effects of DC current on the stress-strain curve and hardness of 6061 T6511 aluminum

The effects of electricity on the mechanical properties of aluminum are investigated with the ultimate goal of establishing a technique by which the mechanical energy associated with cutting a material can be reduced without requiring an increase in the material's temperature. The effects of the electricity on the mechanical properties of 6061 aluminum are investigated through both tensile and hardness testing. As the electricity is passed through the material, resistive heating occurs within the material. Therefore, the effects of non-stationary temperatures on the stress-strain behavior of 6061 aluminum are investigate with and without the electrical current flowing through the material. How the electrical effect varies based on the aluminum's temper is also investigated, along with the effects of electrical pre-treatments. The experimental results indicate that the electricity has the potential to substantially reduce the energy required to machine the material without causing significant increases in the workpiece temperature. The testing also indicates that these effects exist regardless of the temper on the material. Finally, the study found that, while not reducing the energy as substantially as when using a continuous current, an electrical pre-treat can be used to reduce the energy below that found from annealing alone.