Processing Challenges in the Fabrication of In Situ Al-Mg2Si Composite Sheet Through Continuous Casting Route

The present study investigates the challenges associated with manufacturing particle-reinforced in situ Al-Mg2Si composite sheet using a continuous casting route. While production of composite sheets using conventional casting routes is quite challenging and energy-intensive for the manufacturing industries, continuous casting can address many of these challenges, and there is a need to study the inherent issues concerning this. This study examines the design of continuous casting setup, selection of processing parameters (such as casting speed and superheat temperature), material selection criteria to cast composite sheet, and processing defects in the cast components. The research employs stereoscope, optical microscope, field emission scanning electron microscope (FESEM), differential scanning calorimetry (DSC), and % thermogravimetric (TG) analysis to characterize the defects, reinforcement distribution and solidification behavior of the composite sheet. The results indicate that selecting the optimized superheat temperature and roll velocity ensures uninterrupted continuous casting production. The microstructure analysis shows that the solidification shrinkage, macrosegregation, and porosity in the final products are the major drawbacks of the continuously cast composite sheet.