Materials and Manufacturing Processes

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Exemplary encapsulate feeding in stir casting for

quality composites

A. Manivannan & R. Sasikumar

To cite this article: A. Manivannan & R. Sasikumar (2019): Exemplary encapsulate

feeding in stir casting for quality composites, Materials and Manufacturing Processes, DOI:
10.1080/10426914.2019.1566962

To link to this article: https://doi.org/10.1080/10426914.2019.1566962

Published online: 03 Feb 2019.

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MATERIALS AND MANUFACTURING PROCESSES
https://doi.org/10.1080/10426914.2019.1566962

Exemplary encapsulate feeding in stir casting for quality composites

A. Manivannan and R. Sasikumar
Selvam Composites Materials Research Lab, Department of Mechanical Engineering, Selvam College of Technology, Namakkal, India

ABSTRACT ARTICLE HISTORY

The focus of this paper aims at addressing the contemporary issues, i.e., agglomeration and nonuniform Received 20 September
dispersion of reinforcement particles prevailing with stir casting method of fabricating metal matrix 2018
composites. Although it has been dealt with different approaches, viable optimal technique has not Accepted 27 December 2018
evolved so far. A novel encapsulate feeding technique aimed to accomplish uniform dispersion of KEYWORDS
ceramic reinforcement particles. In this research, we have chosen Aluminum Alloy 6061 (AA 6061) as Stir; casting; encapsulate;
a matrix material and cubic boron nitride (c-BN) as a reinforcement companion to form a unique feeding; thermal; properties
combination of advanced aluminum composites to prove this innovative feeding technique.
Two percent of Mg added in every casting as a wetting agent to improve binding nature between
metals and ceramics. The Aluminum Boron Nitride (Al/BN) composites are fabricated through bottom
type of pouring stir casting machine. Metallographic characterization ensures uniform particle disper-
sion. The composites are tested using pin-fin apparatus and Xe-flash laser setup and found enhanced
(12%) thermal properties than pure AA 6061.

Introduction in the crucible, which reacts with moisture in the atmo-

In Aluminum Matrix Composites (AMCs), aluminum is
taken as matrix material and ceramics are used as reinforce-
ment particle, and they combine to form AMCs. The proper-
ties of AMCs shall be customized to the mandate
requirements of various industrial applications through
acceptable combinations of matrix, reinforcement type, size
and shape, and also processing route.[1] AMCs offer an
enhanced amalgamation of properties such as good machin-
ability, lightweight in nature, improved mechanical proper-
ties, and low coefficient of thermal expansion (CTE)
and thus predominant attention paid on engineering this
kind of novel advanced materials.[2] Stir casting is
a simplest and promising processing technique to produce
advanced materials for aviation, structural, marine, aero-
space, defense, and automotive applications due to their
superior mechanical properties. Vortex Stir casting setup
consists of a furnace, reinforcement feeder, and mechanical
stirrer.[3–5] The bottom pouring setup is the appropriate
arrangement in stir casting as the stirred slurry needs to be
transferred into mold instantly to avoid deposition at the
base or foot (bottom) of the furnace. The entire stirrer
assembly is connected with variable speed motor which
controls the speed and rotation of the stirrer by means of
a regulator connected with the motor. Mechanical stirrer
consists of stirring rod and single-stage impeller blade.[6]
Single-stage impeller is most frequently used than two- or
multi-stage impellers to avoid excessive vortex flow.[7] The
foremost process in stir casing is melting of aluminum kept
sphere and forms a layer of aluminum oxide (Al2O3) at
the top.
2Al þ 3H2 O , Al2 O3 þ 6H (1)
This aluminum oxide layer shields and arrests further reaction
with the atmosphere. After attaining certain temperature, the
mechanical stirring starts to create vortex, in a certain while
ceramic particles are fed using feeder in constant feed rate at
the middle of the vortex. Stirring process involves continuous
oxidation of melt, which results in wettability reduction.[5] To
avoid this, the inert gas atmosphere is maintained throughout
the process. In other way, adding wetting agents such as
magnesium improves the wettability between the matrix
material and reinforcement ceramic powders.[8] Apart from
oxidation issue, another major problem frequently faced in
stir casting is achieving homogenous particle distribution in
the molten matrix. Stirring plays a key role in final micro-
structure and improvised properties of fabricated composites
since it controls the dispersion of ceramic particles within the
matrix. Optimum superior properties can be accomplished
through reinforcement particle distribution; uniform distribu-
tion and the agglomeration problem are most common in
many processing techniques, including stir casting.[3,9] Few
researchers have published articles with varying stirring para-
meters which plays a major role in the entire stir casting
process. Therefore, the right selection of optimal parameters
endures the particular purpose of attaining the uniform
dispersion.

CONTACT A. Manivannan manivannandesign@gmail.com Selvam Composites Materials Research Lab, Department of Mechanical Engineering, Selvam
College of Technology, Namakkal 637003, India
Dedication: To My Mentor, Prof. Dr R. Sasikumar
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/lmmp.
© 2019 Taylor & Francis
2 A. MANIVANNAN AND R. SASIKUMAR
By using computational fluid dynamics (CFD), Sahu
and Sahu[10] studied about molten metal fluid flow by
varying impeller size, blade angle, and stirrer speed using
grey Taguchi method. Sun et al.[11] investigated optimal
values of stirring speed, impeller position, and angular
position of rotating impellers to achieve homogenous dis-
persion of reinforcement particles by achieving effective
flow pattern through CFD modeling tool. Kannan et al.-
[12]
have taken stirring speed varying as 400, 600, and
800 rpm, and impeller blade angle varying as 90°, 70°,
and 50° were taken as parameters for optimization and
studied behavior of fluid flow that shows the beneficial
distribution of nanoparticles based on a numerical model
for the manufacturing of nanocomposites through stir
casting. Based on the literature study, feeding technique
is least explored among researchers to achieve uniform
dispersion. This motivates the current research work’s
progressive and successive attempt.
Materials and methods
In stir casting method, to overcome agglomeration and
uneven dispersion of particles and to produce quality
AMCs, novel innovative encapsulate feeding technique is
used. Sequential process is as follows. In this feeding
method, to suit with the crucible, the preliminarily
Figure 1. Three-dimensional model and machined cup with metal cap.
Figure 2. Comparative SEM micrograph.
purchased Aluminum Alloy 6061 solid shaft with 85 mm
outer diameter (OD) machined as a hollow cylindrical cup
shape (as shown in Fig. 1) with the dimensions of 85 mm
outer diameter, 65 mm internal diameter, 150 mm length,
and 30 mm bottom thickness. Next, the reinforcement
particles (5% of cubic boron nitride) kept inside alumi-
num foil sheet (as shown in Fig. 2). Two percent of Mg
conjoined as wetting and binding agent to enhance bond-
ing between reinforcement particles and base metal.[13]
This wrapped ceramic powder and wetting agent are
placed inside a hollow cylindrical cup and closed using
cup cap. The furnace heats up to 850 ̊ C (even though
the melting point of base metal is around 660–680 ̊ C)
and the molten slurry base metal arrests reinforcement
particles in all the directions due to gaseous layer formed
by the base metal. Next, the single-blade graphite-coated
mechanical stirrer agitates to break gaseous region and
reinforcement particle mix up with the base metal. The
speed of the stirrer gradually increases up to 500 rpm for
4 min with argon gas environment to avoid oxidation.[3]
Then, stirrer speed gradually reduced to null (zero) value,
and the composite slurry poured into preheated (500°C)
mold through an arrangement, namely, bottom tapping by
the help of a funnel. Then, it is quickly air quenched to
reduce the time for settling of fragments/molecules (parti-
cles) in the fluid/liquefied matrix.[14] The above cycle is

repeated with varied fractions as 1, 2, 3, and 4 vol.% of
c-BN molecule (particle) reinforcement to fabricate differ-
ent compositions of Al/BN composites.[15]
The tested composite samples are cut into 10 × 10 mm
using an abrasive cutter, and these samples are prepared for
metallographic examinations using 220-320-400-600-800-
1000-1200-1500 emery papers accompanied by burnishing
with diamond paste of 0.5–1 µm. The etchings of prepared
samples done according to ASM Handbook Vol .9 through
caustic etching process (10 g NaOH to each 90 mL H2O).
The samples prepared are characterized for elemental ana-
lysis by using energy-dispersive spectra analysis – Genesis
XM4 and scanning electron micrograph examination using
Vega3–TESCAN make microscope available at BMSCE,
Bangalore.
Al/BN composite casted specimens machined and drilled
for testing. The specimen is incorporated (fitted) through
a covering of long slender rectangular duct. With the help of
pin-fin apparatus, testing was conducted, and one end of the
fin projected outside along the duct and the other end is
heated using the heater. A varied range of temperatures
observed at different five points across the entire length of
the sample (fin) was measured using k-type thermocouples.
The arrangement ensures the distribution of temperature
across the entire fin area. The above cycle of experiments
was repeated for all composite specimens and AA 6061 to
make comparison analysis.
Thermal diffusivity and specific heat are estimated using
a Xe-flash laser thermal diffusivity system (make of
AnterCorporation, Flashline 2000, Pittsburgh, PA) available
at NIIST, Trivandrum. The samples used for thermal con-
ductivity characterization are in the form of a circular disc,
with a 12.6 mm diameter and 2 mm thickness in size.
Smoothness and flatness are further enhanced using
a silicon carbide grinding paper of 400 grit size, followed
by coating both sides of the sample with graphite for
thermal contacts in order to avoid reflection of the xenon
discharge light beam.
Results and discussion
Figure 2(a) shows the Scanning Electron Microscope
(SEM) micrograph image of Al/BN composite containing
5% cubic boron nitride (c-BN) casted/fabricated through
stir casting method supported by bottom tapping arrange-
ment by regular feeding technique, and Fig. 2(b) also
shows the SEM micrograph image of the casted specimen
Al/BN composite containing the same 5% cubic boron
nitride (c-BN) produced by encapsulating feeding techni-
que using the same processing route.
In regular feeding, the composites produced are of least
quality with blow holes and breaks many times due to
reinforcement clusters during secondary operations such
as drilling and machining while sample preparation,
whereas the innovative encapsulate feeding casted compo-
sites support as user friendly during secondary operations.
During visual examination, a large fraction of powders
remain on the molten metal surface and adhere to the
MATERIALS AND MANUFACTURING PROCESSES 3
crucible wall. Hence, in regular feeding, powder wastage
is more and also cluster formation gives inadequate
strength to the composite. The yellow encircled in both
the SEM images denotes clusters, red encircled denotes
blow holes, orange encircled denotes empty region where
ceramic particles are not dispersed, and blue encircled
denotes uniformly distributed region. In encapsulate feed-
ing process, the base metal and reinforcement and wetting
agent undergo thermal decomposition, and it forms gas-
eous layer in-between the top and bottom of the wrapped
ceramic particles. Hence, the reinforcement particles are
arrested within the molten metal. This mechanism put
forth an essential uniform dispersion pattern of reinforce-
ment particles rather than regular feeding technique. After
the mechanical stirring process with the argon gas envir-
onment, stirring break their gaseous layer around, and the
arrested reinforcement particle gets distributed into the
liquefied/fluidized matrix material evenly. Thus, reinforce-
ment particle dispersion is uniformly achieved as shown in
Fig. 2(b) in AA 6061 + 5% BN through this innovative
encapsulate feeding technique. This is mainly due to the
migration of nitrogen atoms along with aluminum and
magnesium (wetting agent), which gets thoroughly
involved in the chemical reaction and thrives for an
improved wettability and bonding nature between molten
matrix and ceramic reinforcement. Even at some region,
cubic boron nitride particles interact greatly with each
other convoys to cluster formation.
The Energy Dispersive Spectroscopy (EDS) analysis is one
of the important analysis methods performed in AMC to
identify the reaction between base metal and ceramics. This
elemental distribution analysis result corresponds to the
prepared Al/BN composite of 5% composition. Figure 3
proves the presence of boron, calcium, silicon, magnesium,
aluminum, and nitrogen particles in the composite speci-
men. Some oxides are also formed during sample
preparation.
The below graph plot Fig. 4 displays the enhancement of
thermal conductivity in AA 6061 by adding various per-
centages of ceramic fillers. This interface filler reduces the
contact resistance offered by thermal ambiance in the mol-
ten matrix. The thermal conductivity property purely
depends on heat conduction propagated by diffusion
which solely the material behavior, whereas the coefficient
of heat transfer is a convection property due to the macro-
scopic movement of the air over the solid surface. From the
graph, it evidently shows that by increasing the cubic BN
contents in the Al matrix, there is a decrement in thermal
contact resistance, i.e., it reduces the CTE., so that thermal
conductivity enhances gradually by percentage, whereas in
3% drastic raise denotes peak point even though enhance-
ment continues further. Increase in fillers leads to clusters,
and waste remains non-dispersed in the furnace. Due to
this, after 3%, constant rise in thermal conductivity is
noticed but not drastic rise.
This preliminary result shows that Al/BN composites
having enhanced thermal characteristics. It is clear that
the dispersion of cubic BN particles in Al matrix
4 A. MANIVANNAN AND R. SASIKUMAR
Figure 3. EDS image – Al/BN composite (AA 6061 T6 + 5% BN + 2% Mg).
Figure 4. Comparative thermal properties of Al/BN composites with pure AA 6061 through pin-fin.
augmented the heat transfer of Al alloys because the parti-
cle–matrix interphase lowered the thermal resistance and
allowed more heat.
In the present case, two samples (pure AA 6061 and AA
6061 + 5% c-BN encapsulate feeded) are tested at a different
temperature range from room temperature (28 ° C) to 202 °
C. According to Wiedemann–Franz law, specific heat and
thermal conductivity are indirectly connected through ther-
mal diffusivity of the material. Although there is no direct
correlation between specific heat and thermal conductivity
but with metals having density criterion as predominant
factor, they are interlinked to calculate thermal diffusivity.
Likewise, here at around 100 ° C, specific heat and thermal
conductivity attain peak point, and this results closet to the
values of pin-fin experimental calculation. All these proper-
ties are nonlinear in nature. The deviation is not higher
than 2% from experimental findings of pin-fin to auto-
mated calibrated instrument readings as in Fig. 4. As the
thermal diffusivity of the material is directly proportional
to thermal conductivity with respect to time, the increase in
its value simultaneously noted down with conductivity
evenly.
Conclusions
Encapsulate feeding process is the best and efficient way to
produce good-quality Al/BN composites in stir casting
method of fabricating AMCs without wasting ceramic rein-
forcing powders. In pin-fin apparatus, when thermal diffu-
sivity increases, heat transfer coefficient (Fig. 3) and
thermal conductivity (Fig. 3) of the fabricated AMCs
enhance irrespective of constant specific heat values under
natural convection without insulation. The fabricated Al/
BN composites of varied composition exhibit high thermal

Figure 5. Comparative thermal properties of Al/BN composite with pure AA 6061 using Xe-flash.
conductivity properties compared with the same sort of
presently used heat transfer aluminum alloys, especially in
electronics, in heat sinks, and also for various applications.
This constitutes the exceptional expectation for enhance-
ment of heat transfer. The probable advantage of the Al/BN
composites such as further characterization and analysis of
mechanical properties will be estimated in the future as
an extension work of this research.
Acknowledgments
The authors wish to thank institutes NIIST, Trivandrum, and BMSCE,
Bangalore, for characterization support and indebted to Mr Logesh, Ph.
MATERIALS AND MANUFACTURING PROCESSES 5
D. Researcher at HKUST. The writers of this paper are willing to pay
back as heartfelt gratitude for funding this research work by SERB and
DST (YSS/2015/000823) and also to Selvam College of Technology
management for their consistent motivation and support to carry out
this work progressively at Selvam Composites Materials Research Lab
(SCMRL). The SCMRL team members Mr S. Prakash (AP/Mech) and
Mr R. Madeshwaran (Technician) are also acknowledged here for their
boundless support in this Research Work.
Funding
This work was supported by the Science and Engineering Research Board
[YSS/2015/000823-
6 A. MANIVANNAN AND R. SASIKUMAR
SERB] and Aeronautics Research & Development Board of DRDO
(ARDB/01/2031808/M/1).
ORCID
A. Manivannan http://orcid.org/0000-0001-9416-1267
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