Study the effect of stirrer design on the stirring performance of ceramic particle reinforcements in stir casting of Aluminum Matrix Composites

Abstract

Stir casting is one of the vital methods for making aluminium alloy matrix composites. The main challenge of this technique is getting a homogenous dispersion of reinforcement particles. The uniform distribution of reinforcement particles improves the mechanical properties, so the stirrer must be designed so that it achieves uniform distribution. The main process of stir casting is done in a closed crucible at high temperature with a hidden flow pattern under a variety of various influencing variables; therefore, numerical is more realistic than the analytical approach for forecasting problems. This paper aims to choose the most efficient stirrer design among four different stirrers to attain the best reinforcement particle distribution in the least time in a selected case. ANSYS CFX, the Image process, and visual experiments were conducted to select the optimal stirrer design. This study is unique in that it provides a new methodology for optimizing the stirrer design, and identifying simulation obstacles and future simulation scope for the mixing performance simulation programmers. Finally, any effort to improve mixing efficiency will very certainly result in lower total energy use, fossil fuel consumption, and CO2 emissions, which is the goal of the millennium.

Taguchi optimization and modelling of stir casting process parameters on the percentage elongation of aluminium, pumice and carbonated coal composite

“…Stir-casting techniques are currently the simplest and most commercially viable method of manufacturing metal matrix composites. This method entails mechanically mixing of the reinforcement particulate in a molten metal bath and then transferring the mixture to a formed mould until it solidifies fully 15 . The experimental set-up includes a resistance-heating furnace to melt the base metal, a feeding mechanism for ceramic particles, and a mechanical stirrer coupled to an electrical motor to mix the pre-heated particles with the matrix liquid 16 .…”