Study on particle distribution in A356/SiCp upward suction castings

Area of Science:

• Materials Science
• Metallurgy
• Composite Materials

Background:

• Metal matrix composites (MMCs) offer enhanced mechanical properties.
• Uniform distribution of reinforcing particles is crucial for MMC performance.
• Casting processes can lead to particle segregation in MMCs.

Purpose of the Study:

• To quantitatively measure silicon carbide particle (SiCp) distribution in A356 aluminum alloy castings.
• To simulate and validate the particle distribution during the casting process.
• To understand the effect of particle size and fraction on SiCp segregation.

Main Methods:

• Production of cylindrical A356-5%50 μm SiCp and A356-10%100 μm SiCp castings.
• Quantitative measurement of SiCp fractions along the casting height.
• Euler-Lagrangian simulation of composite slurry and particle flow.
• Experimental validation of simulated SiCp distribution.

Main Results:

• SiCp fractions decreased significantly with increased filling distance in A356-10%100 μm SiCp castings.
• SiCp fractions varied only slightly in A356-5%50 μm SiCp castings.
• Particles aggregated near the mold wall at the beginning of filling.
• Particles concentrated in the center and depleted near the wall at the casting front.

Conclusions:

• Particle size and fraction significantly influence SiCp distribution in A356 alloy castings.
• The casting process parameters and particle characteristics dictate segregation patterns.
• Simulation models accurately predict SiCp distribution, aiding in process optimization.