Simulation and experimentation of centrifugal casting of functionally graded Al-B₄C composite

The present paper deals with the simulation of the horizontal centrifugal casting process to produce AA6061-15wt% B₄C functionally graded composite with its experimental validation. A hollow functionally graded composite cylinder of dimension OD 110 mm × ID 77 mm × L 110 mm is fabricated under the centrifugal speed of 1200 rpm. Simulation work has been performed on ANSYS FLUENT. Boron carbide (B₄C) reinforcement particle distribution is validated against the simulation results at the different zones of as-cast functionally graded aluminum matrix composite (FGAMC). Experimental results as the volume fraction of B₄C particles at outer (34%), middle (20%), and inner (2.5%) zones closely align with simulated findings at outer (32.5%), middle (18%), and inner (1.8%) zones, confirming the efficacy of the simulation model. Microhardness testing reveals a correlation between particle distribution gradient and hardness, with values decreasing radially inward from 472 to 57 HV. Further casting quality is assessed by density and porosity measurement. The density and porosity gradients are also observed along the radial direction of as-cast FGAMC. The highest tensile strength of 224 MPa was observed for the higher particle-concentrated region.