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Aluminium (Al) and its constituent alloys has been consistently favoured as a promising material for industrial applications. In conventional casting technique of Al alloys, alloying elements are amalgamated in molten pool of Al melt followed by manual skimming. In contrast, batch type manufacturing includes intrinsic mixing and casting discontinuity, which negatively impacts the flexibility and cost-effectiveness of the process, resulting in a decline in the overall efficacy of the process. In the present study, a novel continuous casting processing route has been used to make Al–Cu binary alloys of different compositions. The newly designed technique makes use of a novel mechanical force convection technology, as well as bottom feeding of the molten metal and alloying element throughout the manufacturing process. The bottom feeding along with rotational swirl ensures better amalgamation of alloying element. Feed rates of Al melt and Al–Cu master alloy were mathematically modelled to obtain the desired alloy composition. The microstructural characterization of the developed alloys exhibit Al–Cu intermetallic phase invariably distributed throughout the sample, which concludes a better performing processing route to prepare Al–Cu binary alloys.

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