Simulation and experimental investigation of centrifugal-cast functionally graded aluminum-B4C composite

The present work investigates the flow behavior simulation and experimental validation for Al 6061-10 wt% B4C functionally graded aluminium matrix composite (FGAMC) by varying rotational speeds in a horizontal centrifugal casting (HCC) mold. A three-dimensional computational fluid dynamics model considering particle transportation and solidification based on the multiphase volume of fluid was analyzed using Ansys Fluent software. Simulated Particle gradient formation was validated against experimental data of solidified Al/B4C FGAMC. Simulation and experimental results showed 6.06% and 8.11% thinner outer region for mold speed from 1200 to 1400 rpm respectively. On the contrary, a 27% and 37% broadened thickness was observed at the inner zone for the same. The simulation and experimentation are in good agreement, and results show the formation of B4C particles gradient from outer to inner zone of FGAMCs. In addition, the effect of centrifugal speed on solidification rate and particle distribution has been explored.