‫جزء له عالقة بالجزء األخير من المحاضرة األخيرة في مقرر هندسة السباكة‬

Unit of dispersing solid particles into

Molten Al-alloys
Figure (24) illustrates the modified apparatus used for dispersing SiC
particles into molten Al-Si alloys.
The constructed apparatus consists of an electrical resistance holding
furnace, stainless steel crucible and mixing assembly for agitation the melts.
The mixing assembly located on the top of the furnace is co-axially
aligned through a ball bearing block just above the crucible; the stirring rotor
made of stainless steel has a circular cross- section of 10 mms in diameter.
The blades were made out of 2 mm thick stainless steel plate, which were
twisted to appropriate angles. The overall blade dimensions are 40 mms in
diameter and 12 mms in height. The diameter of blades should be about 0.35
times of the diameter of the crucible in order to obtain a good suspension of
solid particles in the liquid.
A protective refractory coating was applied to the stirring shaft and the
blades to prevent interaction with the molten metal. The refractory coating
used was a carbon wash.

Preparation and casting of the composites:

1- A pre - weighed quantity (700 g) of the Al - Si alloys were melted in
stainless-steel crucible using an electric furnace, the temperature was
controlled and measured with a chromel–alumel thermocouple set at the
center of side wall of the crucible as shown in Figure (24).

2- the temperature was controlled to give a fixed amount of superheat of 50

o
C for all compositions and was closely monitored in order to avoid
overheating.
 Fig. 24 Schematic illustration of the apparatus used for dispersing SiC
particles into molten Al-alloys.

3- The melting temperatures for pure aluminum, Al - 5wt% Si, Al - 7 wt %

Si, Al - 9 wt % Si and Al - 12 wt % Si were 660, 638, 622, 600 and 577 oC
respectively. The alloy in the crucible has been completely melted and kept
at the desired temperature for a period of half an hour for the
homogenization of the melt.

4- the mechanical stirrer blades were positioned below the surface of the
melt; the rotation speed of the stirrer was maintained at 1400 r.p.m. To
create the necessary vortex. A pre - weighed amount of SiC particles (17.5,
35, 52.5 and 70 grams for each trial), preheated at 900 oC for one hour, are
introduced into the molten melt by a feeder device which is positioned so
 that the particles enter the melt between the rotor and the crucible wall.
Silicon carbide particles were added slowly (to an approximate rate of 30
g/mm), as when added at higher rates the particles became agglomerated.

5- Stirring was continued until interface interactions between the particulates

and the matrix promoted wetting. The stirrer was then stopped and
withdrawn.

6- the crucible was then removed from the electric furnace and the oxide film
at the top of the melt was skimmed off and the melt was gently stirred
with coated stainless steel rod to avoid particle setting.

To obtain a uniform distribution of SiC particles the cooling rate during

solidification should be higher.

Squeeze Casting
Squeeze casting, also known as liquid- metal forging, is a process by
which molten metal solidifies under pressure within closed dies positioned
between the plates of a hydraulic press. The applied pressure and the instant
contact of the molten metal with the die surface produce a rapid heat transfer
contact that yields a pore-free fine-grain casting with mechanical properties
approaching those of a wrought product.
Squeeze casting is simple and economical, efficient in its use of raw
material, and has excellent potential for automated operation at high rates of
production .The process generates the highest mechanical properties
attainable in a cast product. The microstructural refinement and integrity of
squeeze cast products are desirable for many critical applications.

To produce MMCs using this process a mass ……….

 Stir Casting and Compo-casting

In some cases it is possible to introduce particulate or short-fiber

reinforcements simply by feeding into the vortex region produced by
vigorously stirring the molten metal. Long stirring times may be necessary to
develop a good bond between the two components, and the volume fraction
of the reinforcement may be limited to about 10% by the rapid increase in the
viscosity of the mixture with the further addition of reinforcement.
Differences in density between molten metals and reinforcing fibers or
whiskers may mean that separation of the two components will occur due to
gravitational force if simple mixing of the fibers in molten metal is attempted.
The tendency to separate can be reduced or eliminated in compo-casting
whereby stirring takes place as the metal undergoes solidification. Under
these conditions, mixed phases of solid and liquid metal can coexist in the
form of slurry in which reinforcement particles can be mixed and become
trapped between the solid phase regions with uniform dispersion.
Squeeze Casting Process outline
For an explanation as shown in Fig. 26 to produce Al-SiCp composites, the
following procedure was followed in the squeeze casting process.
1- Al-Si alloys or composites were melted in a stainless steel crucible in
the electric resistance furnace and the pouring temperature was controlled to
give a fixed amount of superheat of 50 oC for all compositions, the
temperature was closely monitored with a thermocouple in order to avoid
overheating.
2- The crucible was then removed from the electric resistance furnace and
the oxide film on top of the melt was skimmed off.
3- Before each press cycle, the dies were sprayed with a thin coating of
graphite powder mixed with isopropyl alcohol to prevent the adhesion of
metal to the die walls, then pre-heated to 500 oC inside the electric resistance
furnace located on the bed of a hydraulic press.
4- The molten alloys or composites were poured into the preheated die
cavity, located in the bed of a 200-ton hydraulic press.
 5- The squeeze casting punch mounted to the press ram was preheated,
then allowed lowered and squeezing the melt at constant pressure, the squeeze
casting experiment was repeated at four different pressures, squeezing was
done as rapidly as possible after pouring so that only a small amount of
solidification can occur before applying the pressure.

Figure 26 Schematic illustration of the set-up employed for squeeze

casting
6- The pressure was held on the molten alloys or composites until
solidification was completed for duration of about 15 min.
7- After complete solidification, the die was allowed to cool by a stream
of pressurized air. After cooling the casting was ejected form the mould and
examined carefully for signs of external defects and then sectioned
longitudinally into six slices for mechanical and metallographic testing.
 Some ingots were also prepared without the application of pressure by
using the same procedure for comparison.

Figure (27) represents the main steps of squeeze casting process.

 Process Variables
There are a number of variables that are generally controlled for the
soundness and quality of the castings. The variable ranges discussed in the
following sections vary with the alloy system and part geometry being
squeeze cast.
Melt Volume: Precision control of the metal volume is required when
filling the die cavity. This ensures dimensional control.
Casting Temperatures depend on the alloy and the part geometry. The
starting point is normally 6 to 55 oC above the liquidus temperature.
Tooling Temperatures ranging from 190 to 316 oC are normally used.
The lower range is more suitable for thick-section casting. The punch
temperature is kept 15 to 30 oC below the lower die temperature to maintain
sufficient clearance between them for adequate venting. Excess punch-to–die
clearance allows molten metal to be extruded between them, eroding the
surface.

Time Delay is the duration between the actual pouring of the metal and
the instant the punch contacts the molten spool and starts the pressurization
of thin webs that are incorporated into the die cavity. Because increased
pouring temperatures may be required to fill these sections adequately upon
pouring, a time delay will allow for cooling of the molten pool before closing
of the dies to avoid shrink porosity.
Pressure Levels of 50 to 140 MPa are normally used, 70 MPa is generally
applied, depending on part geometry and the required mechanical properties.
There is an optimum pressure for each of the systems after which no added
advantages in mechanical properties are obtained.