Development of low machining cost materials by using aluminum borate

6061 aluminum alloy composite reinforced with α-alumina and aluminum borate is fabricated by casting method. The above mentioned composite has been compared to a similar composite without aluminum borate reinforcement for their machinability. The aluminum borate filler was controlled up to (2.5, 5.0 and 30vol %) on the surface of α-alumina. The reaction zone between alumina and the matrix in both the systems are analyzed with the help of TEM micrographs as well as X-ray diffraction profiles. At the reaction zone between alumina and the aluminum alloys, some spinel-like compounds (MgAl₂O₄) are identified. Finally, machinability was analyzed with the single point tool machining.