Applying visualization techniques to study the fluid flow pattern and the particle distribution in the casting of metal matrix composites

Abstract

Abstract For a past few decades, metal matrix composite has a significant role in the various industrial and automobile applications. Production of metal matrix composite using stir casting technique is one of the most effective and economical technique. Achieving the uniform distribution of the reinforced particles was the major problem facing during the production of particle reinforced metal matrix composites and also achieving the effective fluid flow pattern was the greatest challenge to the research community. In this research, some of the major stir casting process parameters such as blade geometry, stirring speed and impeller position were optimized based on the vortex height of the fluid and settling time of the reinforced particles using visualization experiments and Grey relation analysis. Flow pattern of the fluid and the trace of the particles was analysed using a new technique called streak photography. Streak photography was one of the visualization experiments using glycerol water based model. Al8011/SiC metal matrix composites were manufactured based on the optimized stir casting process parameters. Finally, the fabricated composites were carried out for OM, SEM analysis and Brinell hardness testing for confirming the uniform distribution of the reinforced particles. Based on the confirmation results, 45ᴼ stirrer blade angle, impeller position 40 % from the base and 250 rpm stirring help to produce uniform distribution of the particles.