BOTTOM-POURING FURNACE FOR PRODUCTION OF

ALUMINIUM MATRIX COMPOSITES

Mohd Harun, Hafizal Yazid, Shaiful Rizam Shamsudin, Hishamuddin Husain, Zaiton
Selamat and Mohd Shariff Sattar
Industrial Technology Division, Malaysian Institute For Nuclear Technology Research
(MINT),
Bangi 43000 Kajang, Selangor

ABSTRACT

A full control of the processing parameters is needed to obtain a well distribution of

reinforced particles in the metal matrix composites. One of the method used in producing
the composite is stir casting technique. The conventional technique employs manual
stirring, no control of crucible atmospheric condition and pouring is carried out manually
which introduce various impurities in the melts. In solving the problem, bottom pouring
furnace was designed at MINT’S Material Technology Laboratory to produce Al alloys
and metal matrix composite. The conceptual design of the apparatus imparts controlling
the homogeneity of the melts via automated stirring, controlling the crucible atmospheric
condition via gas purging and bottom pouring for reduction of impurities in casting.
Currently, the bottom pouring furnace is being used in the fabrication of stir-cast
aluminum metal matrix composite (MMC) materials. The paper discussed the design,
development and production of aluminum based composite using the MINT`S bottom
pouring furnace.

Keywords: Bottom pouring furnace; Stir casting; Metal Matrix Composites; Stirring
Speed; Reinforced Particles

1. Introduction

The aim involved in designing a furnace is to produce metal matrix composite with
homogeneous distribution of reinforcement particles, essential for optimum mechanical
properties. A stir casting process is carried out by using a furnace completed with a
controlled temperature system and stirring speed. The process involves producing a melt
of the selected matrix material, followed by introduction of a reinforcement material into
the melt, obtaining a suitable dispersion through stirring. The melt containing stirred
particles is solidified in the mould to obtain desired distribution of the dispersed phase in
the matrix. The particle distribution in the matrix depends on process parameters during
both the melt and solidification stages of the process [1]. The parameters are viscosity of
the liquid, heat transfer rate, wettability of materials, stirring method, agglomeration of
the reinforcement before and after mixing, and pattern or mould shape and temperature.
High speed of impeller rotation is needed to ensure an even distribution of less dense
reinforcing particles throughout the denser metal matrix. The stir casting process is more
suitable for making composites which contain up to 30 volume percentage of particulate
dispersoids. The composites can include combinations like metal-fly ash, metal-oil ash,
metal-graphite, metal-silicon carbide, metal-carbon etc. The combination with low cost
reinforcement particles such as fly ash will result in significant decreases in cost of
components, and significant improve machinability, wear resistance and damping
capacity [2]. The stir casting is generally accepted as a particular promising route because
of its simplicity, flexibility and applicability to large quantity production. It also
minimizes the final cost of product.

This paper provides a review method in producing of MMC using stir casting techniques
with a bottom pouring furnace developed at MINT. The quality of the product obtained
through this technique also will be discussed.

2. Experimental

2.1 Composite Preparation

The cleaned and weighed 0f 1500g aluminum ingot are super heated above its melting
temperature (732oC ) in a bottom pouring composite melting furnace. The melting also
will be degassed with argon gas to reduce the gas bubbles in the melt. At the same time,
stirring is initiated to homogenize the temperature. Cast iron coated with ceramic
propeller is used for the stirring. The propeller is attached to a variable speed motor with
maximum speed of 3000 rpm. The impeller is fabricated in accordance with the law of
fluid flow and particle movement to create vortex motion. The depth of impeller shall be
immersed approximately one third of the height of the molten metal from the bottom of
the crucible. The temperature and stirring speed are noted. At this temperature the
preheated fly ash particles (650oC) will be introduced into the melt surface of the Al melt
at a rate of 70g/min to 120g/min and melting temperature of 1350oF(732oC), along with
Mg pieces weighing a total of 1% by weight of melt in order to improve the wettability.
The temperature during the addition of fly ash particles is raised gradually and stirring is
continued until interface between particles and matrix promotes wetting. The melt is then
superheated above liquidus temperature of about 700-770oC and then poured into a
permanent mould. In order to get uniform distribution of fly ash, the composite melt have
to be stirred continuously till it is poured into the mould. The same procedures applied to
SiC particles except the Aluminium melt is superheated above liquidus temperature of
about 730-800oC.
 2.2 Furnace Design

The schematic diagram and photo of the MINT`S furnace are shown in Figure 1 and 2
respectively.

Figure 1: Furnace schematic diagram. Figure 2: Furnace photo.

2.3 Parameters To Be Considered

In preparing metal matrix composites by the stir casting method, there are several factors
to be considered:

i. Difficulty of achieving a uniform distribution of the reinforcement

particles,
ii. Wettability between the reinforcement particles and matrix,
iii. Porosity in the cast metal matrix composites, and
iv. Chemical reaction between the reinforcement particles and matrix.

In order to achieve optimum properties of MMC, distribution of the reinforcement

particles in the matrix must be uniform, bonding or wetting between the reinforcement
particles and matrix should be optimized, the porosity level should be minimized and the
chemical reaction between the reinforcement particles and alloy matrix must be avoided.
 Figure 3: Stirring set-up.
Figure 4: Heating of permanent mould.
Figure 5: Sample removal. Figure 6: Tensile test piece sample.

3. Results and Discussion

Some of the important parameters are given in Table 1.

 Table 1: Processing parameters of Al-fly ash and Al-SiC composites.
Al-fly ash composites Al-SiC composites
Melting Temperature (C) 700-770 730-800
Pouring Temperature (C) 770 800
Stirring Speed (r.p.m) 1200 1200
Impeller angle () 5 5
Mould temperature (C) 350 350

3.1 Morphology and EDS Analysis

3.1.1 Optical Microscopy

Optical microscopy carried out on the as-cast samples of Aluminium-5% fly ash and
Aluminium-5% SiC. The morphology of Aluminium-5% fly ash and Aluminium-5% SiC
are shown in Fig. 7 and Fig. 8 respectively. The present of small amount porosity and
clustered of SiC and fly ash particulates are observed. However, at many locations, free
of porosity and particulates are also observed.

The samples are cut, polished and observed under optical microscope.

Figure 7: Al-fly ash composites Figure 8: Al-SiC composites for comparison

3.1.2 Scanning Electron Microscopy and EDS Analysis.

The results of electron microscopy on as-cast samples of Aluminium-5% fly ash and
Aluminium-5% SiC are shown in Fig. 11 and Fig. 18 respectively. They reveal poor
interfacial bonding between dispersed particles and the matrix. Mg and Si segregation
have been determined by using EDS analysis.
Figure 9: Fly ash particles Figure 10: EDS of fly ash particles

A
B C D

Figure 11: Microstructure of Al-fly ash Figure 12: EDS on spot A, small round
composites. Spot A-E are fly-ash.
subjected to EDS analysis.
Figure 13: EDS on spot B, Al matrix. Figure 14: EDS on spot C, square fly ash.

Figure 15: EDS on spot D, silicon flake. Figure 16: EDS on spot E, big round fly ash.

Figure 17: Poor bonding between fly ash and Al matrix.

Figure 19: EDS on spot F, Al matrix.

Figure 18: Microstructure of Al-SiC
 composites.

Figure 20: EDS on spot G, SiC particle. Figure 21: Good bonding between SiC and
Al matrix.

4. Conclusions

From the morphology analysis of the samples, several conclusions could be drawn:

a) The bottom pouring furnace is suitable in producing metal matrix composites

(MMC’S).

b) Process parameters play vital role in getting uniform distribution of reinforcement

particles. The parameters are viscosity of the liquid, heat transfer rate, wettability of
materials, stirring method, agglomeration of the reinforcement before and after mixing,
pattern or mould shape and temperature and optimum speed of impeller.

c) Process parameters are very unique and applied based on the composites system.
Further research works have to be implemented to optimize all the processing
parameters. Heat treatment is proposed to enhance the interfacial bonding between the
reinforcement and the matrix.

d) The preparation of metal matrix composites (MMC’S) with low-dense reinforced

particles (Al-fly ash composites) is difficult as compared with the high-dense
reinforced particles (Al-SiC composites).

Acknowledgements

We would like to thanks to Dr Abd. Nassir Ibrahim, Director of Industrial Division, Dr

Azali Muhamad, Head of Materials Technology Group, MINT for their advice and
valuable discussion. We would also like thanks to MOSTE for providing a research grant
(IRPA 03-01-03-0009-EA001).

References

[1] J. Hashim et al., J. Mater. Processing Technology Vols. 123 (2002) 251-257
[2] P. K. Rohatgi et al., Key Eng. Mater. Vols. 104-107 (1995) 283-292