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Research Papers

Optimization of Stirring Parameters Through Numerical Simulation for the Preparation of Aluminum Matrix Composite by Stir Casting Process

[+] Author and Article Information
Hai Su, Hui Zhang, Hongbo Liu

College of Materials Science and Engineering, Hunan University, Changsha 410082, China

Wenli Gao1

College of Materials Science and Engineering, Hunan University, Changsha 410082, Chinahudasuhai@yahoo.cn.

Jian Lu, Zheng Lu

 Beijing Institute of Aeronautical Materials, Beijing 100095, China

1

Corresponding author.

J. Manuf. Sci. Eng 132(6), 061007 (Nov 09, 2010) (7 pages) doi:10.1115/1.4002851 History: Received February 28, 2010; Revised September 24, 2010; Published November 09, 2010; Online November 09, 2010

The flow behavior of the fluid has a significant effect on the particle distribution in the solid-liquid mixing vessel. The stir casting process is generally conducted in a closed crucible, in which the flow pattern is invisible. Therefore, numerical simulation is a forceful tool to guide the experimental research. In the present study, the fluid flow in the stirred crucible during stir casting has been simulated using finite element method. The effects of some important stirring process parameters, such as the blade angle, rotating speed, the diameter of the impeller, and the stirrer geometry, on the flowing characteristics of the molten matrix have been investigated in order to achieve the effective flow pattern to uniformly disperse the ceramic particles in the molten matrix. The simulation results show that the process parameters have significant effects on the flow behavior of the fluid in the stirred crucible. The various combinations of these parameters are beneficial to generate a suitable condition for the composite casting. Further experimental investigation reveals that the present work can provide a guide for the industrial preparation of aluminum matrix composite with a uniform particle reinforcement distribution by stir casting process.

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Copyright © 2010 by American Society of Mechanical Engineers
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Figures

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Figure 1

The geometrical model of the crucible and the stirrer

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Figure 2

Sketches of the impeller

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Figure 3

Flow patterns in the stirred crucible at the rotating speed of 500 rpm with different stirrers

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Figure 4

Flow patterns of axial cross section in the crucible at the rotating speed of 500 rpm for various blade angles

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Figure 5

Flow patterns of transverse section in the crucible at the rotating speed of 500 rpm for various blade angles

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Figure 6

Flow pattern in the stirred crucible at the different rotating speeds for the multistage stirrer

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Figure 7

Two different circulation profiles in the vessel with the multistage stirrer

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Figure 8

Flow patterns in the stirred crucible at the rotating speed of 1000 rpm for the different d/D values

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Figure 9

SEM images of as-cast SiCp/Al composite prepared at the different rotating speeds for 10 min: (a) 600 rpm, (b) 800 rpm, (c) 1000 rpm, and (d) high magnification of (c)

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