Abstract
The characteristic surface that is generated during orthogonal wire brushing of a flat 6061-T6 aluminum workpart is examined in this paper. Scanning electron microscopy is used for characterizing the surface topography, whereas subsurface microstructure and properties of the brushed region are evaluated by both metallography and microhardness measurements. The unique topographical characteristics of the contact zone suggest material removal and subsequent redeposition onto the workpart. On the basis of the experimental observations, a qualitative theory is advanced which identifies transfer mechanisms for removal and redeposition of aluminum alloy.