SIMULATION OF STIR CASTING PROCESS FOR MANUFACTURING OF MMC

Abstract

Non-homogeneous particle distribution is one of the greatest problems in cast metal matrix composites (MMCs). To optimize some of the parameters for uniform particle distribution for stir casting, the present simulation studies were conducted. For computational simulation, the liquid aluminium is used as a primary phase and SiC particles used as a secondary phase in the simulation fluid mixtures. Scaled-up computational simulation was carried out in a crucible with varying blade angle of the stirrer. The dependence of the computational analysis; the stirrer geometry and stirring, speed were seen to affect the particle dispersion and settling times and blade angle. Results are discussed in terms of their applicability to MMC production This examines the effect of blade angle during Al—SiC MMC production. Processing periods (up to 7min), stirring speeds (300-600rpm), and re-enforcement sizes (10μm) at viscosity levels (1MPa-s) were investigated. Volume fraction results of SiC at different locations within the fluids were assessed by each of these methods and compared. From these tests, a stirring speed of 600 rpm for 0=45° was found to be best in order to produce uniform distributions of Sic. In order to obtain a uniform re-enforcement distribution in the lower viscosity system, stirring periods were found to range from 15 to 190 sec.