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The flow behavior of the fluid has a significant effect on the particle distribution in the solid-liquid mixing vessel. The stir casting process is generally conducted in a closed crucible, in which the flow pattern is invisible. Therefore, numerical simulation is a forceful tool to guide the experimental research. In the present study, the fluid flow in the stirred crucible during stir casting has been simulated using finite element method. The effects of some important stirring process parameters, such as the blade angle, rotating speed, the diameter of the impeller, and the stirrer geometry, on the flowing characteristics of the molten matrix have been investigated in order to achieve the effective flow pattern to uniformly disperse the ceramic particles in the molten matrix. The simulation results show that the process parameters have significant effects on the flow behavior of the fluid in the stirred crucible. The various combinations of these parameters are beneficial to generate a suitable condition for the composite casting. Further experimental investigation reveals that the present work can provide a guide for the industrial preparation of aluminum matrix composite with a uniform particle reinforcement distribution by stir casting process.

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