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

Abstract

Aluminium matrix composites, which are a subclass of metal matrix composites, have characteristics including low density, high stiffness and strength, better wear resistance, controlled thermal expansion, greater fatigue resistance, and improved stability at high temperatures. The scientific and industrial communities are interested in these composites because they may be used to manufacture a broad variety of components for cutting-edge applications. This has study observed how the stirring speed, processing temperature, and stirring duration of the stir casting process affected the percentage elongation of Al-Pumice (PP)-Carbonized Coal Particles (CCP) hybrid composites. It also looked at the optimal weight of these natural ceramic reinforcements using the Taguchi optimization technique. While optimizing the percentage elongation property, the hard compound such as silica, iron oxide, and alumina, were discovered during the characterisation of the reinforcement, showing that PP and CCP can be used as reinforcement in metal matrix composite. The percentage of elongation of the hybrid composite was shown to be most affected by the PP, followed by processing temperature, stirring speed, CCP, and stirring time, using stir casting process parameter optimization. It was observed at 2.5 wt% of pumice particles, 2.5 wt% of carbonated coal particles, 700 °C processing temperature, 200 rpm stirring speed, and 5 min stirring time, the optimum percentage of elongation was discovered to be 5.6%, which is 25.43% lower than the percentage elongation of Al-alloy without reinforcing. The regression study developed a predictive mathematical model for the percentage elongation (PE) as a function of the stir casting process parameters and offered a high degree of prediction, with R-Square, R-Square (adj), and R-Square (pred) values of 91.60%, 87.41%, and 79.32% respectively.

Optimization and statistical modeling of the thermal conductivity of a pumice powder and carbonated coal particle hybrid reinforced aluminum metal matrix composite for brake disc application: a Taguchi approach

“…Aluminum (Al), iron (Fe), silicon (Si), and magnesium (Mg) are the peaks for the EDS analysis shown in figure 4(b). These elements confirmed that the alloy used was Al 6061 alloy, which validated the results of the XRF analysis and agreed with the findings of Ibrahim et al (2023b).…”

An Investigation of the Thermal Properties of LM13- Quartz- Fly-Ash Hybrid Composites

“…The fabrication route selected should be cost-effective and should ensure a uniform distribution of the selected particles within the matrix. Liquid state processing such as melt stir casting is considered to be an effective method to fabricate particulatereinforced AMCs [32,33]. Stir casting is one such processing route which has universal commercial acceptability to fabricate AMCs owing to its flexibility, ability to cast intricate geometries and cost-effectiveness [34,35].…”

Effect of Calcined Eggshell Particles on Some Properties and Microstructure of Al-Si-Mg Alloy

“…Extensive research has demonstrated that there is no significant difference in quality between virgin and recycled aluminum alloys. Moreover, incorporating aluminum scraps in the green manufacturing of aluminum alloys/composites for engineering applications offers two advantages: substantial reductions in energy consumption and decreased greenhouse gas emissions associated with primary aluminum production from ore [2][3][4][5].…”