Investigation on the Effect of Stirring Process Parameters on the Dispersion of SiC Particles Inside Melting Crucible

Stirring based liquid metal processing is the widely explored process by researchers for the production of metal matrix composites (MMCs). The dispersion of reinforcement particles is the major challenge in the process. The stirring process parameters govern the dispersion of reinforcement particles in MMCs. The important stirring process parameters are stirring speed, stirrer geometry, stirrer position, and stirring time. In the literature, research works are reported, where the effect of such parameters on the dispersion of particles was investigated either by analyzing flow field using computational methods (assuming constant fluid properties) or by sectioning the casted samples. In cast condition, the dispersion of particles is also influenced by the solidification phenomena. The aim of the present work is to investigate the significance and the effect of stirrer geometry, stirrer position and stirring speed on the dispersion of reinforcement particles inside melting crucible, during the stirring. Aluminium alloy LM25 was used as the matrix material and silicon carbide (SiC) particles having mean size 37.58 microns (d(50) value) were used as the reinforcement phases. Samples of the composite slurry during the stirring process were dragged using a quartz tube at three levels inside crucible and microstructure analysis was carried out. Number density (ND) and inter particle distance were evaluated for parameter combinations. The uniform dispersion of SiC particles was observed at 45 degrees stirrer blade angle, 400 rpm stirring speed and 40 mm stirrer position. And, significance order of individual parameter was observed as stirring speed < stirrer position < stirrer blade angle. Graphic Abstract