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% B 4 C 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...

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Bibliographic Details
Published in:International journal on interactive design and manufacturing 2024-08, Vol.18 (6), p.3861-3871
Main Authors: Verma, Rupesh Kumar, Chopkar, Manoj Kumar
Format: Article
Language:English
Subjects:
Aluminum
Aluminum base alloys
Aluminum boron carbide
Aluminum matrix composites
CAE) and Design
Casting
Centrifugal casting
Computer simulation
Computer-Aided Engineering (CAD
Concentration gradient
Density
Electronics and Microelectronics
Engineering
Engineering Design
Heat conductivity
Industrial Design
Instrumentation
Mechanical Engineering
Microhardness
Original Article
Particulate composites
Porosity
Simulation models
Software
Solidification
Tensile strength
Viscosity
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Summary:The present paper deals with the simulation of the horizontal centrifugal casting process to produce AA6061-15wt% B 4 C 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 (B 4 C) 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 B 4 C 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.
ISSN:1955-2513
1955-2505
DOI:10.1007/s12008-024-01819-w