Effect of Processing Parameters of Rheocast on Mechanical Properties of Al–10.5Si–1.7Cu Alloy

The current work examines the results of an experimental study for the liquid casting of an aluminum‐6061‐5 weight % fly ash cenosphere composite by employing stir casting. The studies were conducted using the response surface methodology (central composite design L16 experiments) with three process factors (stirring temperature, stirring speed, and stirring time) at three different levels. An attempt has been made to determine the impact of process variables on the degree of sphericity and particle size. The optimal processing conditions for the best degree of sphericity (0.765) and particle size (93.227 μm) are identified as A−1, B+1, and C+1, corresponding to a stirring temperature of 670 °C, a stirring speed of 600 min−1, and 15 min stirring time. Based on the analysis of variance analysis, the degree of sphericity and particle size evolution is significantly influenced by stirring time followed by temperature and speed. Additionally, a mathematical model for the evaluation of the degree of sphericity and particle size in the primary‐aluminium phase has been developed and it shows good consensus with the experiments.

Section: Degree Of Sphericity and Particle Sizesupporting

confidence: 55%

Experimental investigation and optimization of morphological characteristics in mechanically agitated aluminium 6061‐fly ash cenosphere composite

Anand,

Tiwari,

Prakash

2023

“…Because it directly impacts morphological properties in a stir-cast metal matrix composite, the first order of weight % of reinforcement is the most important factor for hardness. The tensile characteristics are significantly influenced by a modified (equiaxed) α-phase of aluminium alloy and increased refinement of the eutectic phase [32]. Rest terms in the model have a substantial impact on hardness.…”

Section: Statistical Investigation For the Developed Mathematical Mod...mentioning

confidence: 99%

Optimization of process variables and characterization of mechanically agitated ceramic‐microsphere reinforced aluminium composite

Anand,

Tiwari,

Prakash

et al. 2024

This study aims to investigate the effect of stir‐casting process parameters, including stirring speed, stirring time, and weight % of the ceramic microsphere, on the fabrication of an aluminium 6061‐ceramic microsphere composite. Experiments are conducted using a full‐factorial design approach to determine the effect of variables on mechanical properties. A field effect scanning electron microscope is used to analyze the fracture surfaces of the test specimen. Further, the results are subjected to the Anderson‐darling normality test to validate the accuracy of the model, and finally, an analysis of variance is performed to identify the most significant parameters that affect the mechanical properties. The results confirm the validity of the designed experimental model for enhancing the mechanical properties of the aluminium 6061‐ceramic microsphere composite. The optimum mechanical properties are attained for a stirring speed of 600 min−1, stirring time of 15 min, and 5 weight % of reinforcement. Furthermore, the weight percentage of the ceramic microsphere increase, the ductility of the composite decreases while its strength and hardness increase. Finally, the analysis of variance shows that all parameters significantly impact the mechanical properties of the designed composite.

Investigating the influence of ferric oxide grade alumino‐silicate cenosphere particulates and heat treatment on the microstructural evolution and mechanical properties of Al6061/ferric oxide alumino‐silicate cenosphere (x weight %) composite

Anand,

Tiwari,

Prakash

et al. 2024

The main aim of this investigation is to fabricate aluminum 6061 composites with three different weight percentages of ferric oxide grade alumino silicate cenosphere (1 wt.%, 3 wt.%, and wt.%) by the stir‐casting process. The fabricated cast composite and T6 heat‐treated composite is used to obtain a fundamental understanding of various weight percentages of the cenosphere and the influence of heat treatment on the microstructural changes, mechanical characteristics, the mechanism of fracture, and the interface between the aluminum‐matrix and ferric oxide grade alumino‐silicate cenosphere particulates. Tensile and compressive tests with a constant strain rate (0.5 mm ⋅ min−1) were carried out to study the strength and to find a correlation between the various weight fractions of cenosphere and heat treatment. Investigations of the changes in the microstructure of the aluminum ferric oxide grade alumino silicate cenosphere composite and the fractography of the fracture surface are investigated using optical and scanning electron microscope. X‐ray diffraction was utilized to confirm the results obtained from optical and scanning electron microscope analyses for phase characterization validation. A maximum of 30 % increase in hardness value, 20 % increase in tensile strength value, 33 % increase in maximum compressive strength value, and 2 % increase in elongation values are observed in heat‐treated composite when compared to cast composite.