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<p>The major challenges in the stir casting process for achieving sound castings include particle agglomeration, gravitational settling, and porosity formation. These issues primarily arise due to insufficient control over melt hydrodynamics and vortex stability during mechanical stirring. The present work examined the impact of two innovative blade designs, U-shaped and paraboloid-shaped, on the mechanical properties and microstructure of ADC12/silicon carbide (SiC) AMCs. These AMCs are produced through the bottom pouring process of stir casting. The two innovative blades were tested at various rotational speeds as a means of analyzing their effects on vortex formation, particle distribution, and composite properties. The reinforcement material, SiC, was selected due to its high strength, greater wear resistance, and widespread use in the commercial composites industry. The selected SiC has a weight percentage of 8% and an average size of 40–50 µm. The microstructure study showed that the U-shaped blade at 450 RPM resulted in the most uniform particle distribution, refined α-Al dendrite structure, lower porosity, and enhanced interfacial bonding. Scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD) analysis confirmed the presence of stable α-Al and SiC. Microhardness and tensile test peak values are 137.66 HV and 260 MPa, respectively, which also conforms with the microstructural observation of the U-shaped blade at 450 RPM. In contrast, paraboloid blades generated narrow vortices at higher speeds, which resulted in particle clustering and porosity due to insufficient axial and downward flow. This work highlights the important role of stirrer blade geometry and process parameters in fabricating high-performance AMCs, providing the way for application-ready commercial composite manufacturing.</p>

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Effect of Stirrer Blade Geometry on Particle Dispersion and Properties of ADC12/SiC Composites

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Chintan Morsiya,
  • Shailesh Pandya,
  • Vishvesh Badheka,
  • Krunal Mehta

摘要

The major challenges in the stir casting process for achieving sound castings include particle agglomeration, gravitational settling, and porosity formation. These issues primarily arise due to insufficient control over melt hydrodynamics and vortex stability during mechanical stirring. The present work examined the impact of two innovative blade designs, U-shaped and paraboloid-shaped, on the mechanical properties and microstructure of ADC12/silicon carbide (SiC) AMCs. These AMCs are produced through the bottom pouring process of stir casting. The two innovative blades were tested at various rotational speeds as a means of analyzing their effects on vortex formation, particle distribution, and composite properties. The reinforcement material, SiC, was selected due to its high strength, greater wear resistance, and widespread use in the commercial composites industry. The selected SiC has a weight percentage of 8% and an average size of 40–50 µm. The microstructure study showed that the U-shaped blade at 450 RPM resulted in the most uniform particle distribution, refined α-Al dendrite structure, lower porosity, and enhanced interfacial bonding. Scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and X-ray diffraction (XRD) analysis confirmed the presence of stable α-Al and SiC. Microhardness and tensile test peak values are 137.66 HV and 260 MPa, respectively, which also conforms with the microstructural observation of the U-shaped blade at 450 RPM. In contrast, paraboloid blades generated narrow vortices at higher speeds, which resulted in particle clustering and porosity due to insufficient axial and downward flow. This work highlights the important role of stirrer blade geometry and process parameters in fabricating high-performance AMCs, providing the way for application-ready commercial composite manufacturing.