Particle distribution control in cast aluminium alloy-mica composites

A suspension of mica particles (40m diameter and 3.7 thick) obtained in a mechanically stirred Al-4 wt % Cu-1.5 wt % Mg melt was poured and solidified in a variety of moulds under different heat flow configurations. The resulting cast structure showed a non-uniform distribution of dispersed mica particles with mica-depleted and segregated zones due to their flotation before and during solidification. The experimentally observed profiles of mica-free regions deviate significantly from those computed on the basis of Stokes's law and freezing-time computations. In relatively thick castings, segregation of mica could be minimized by using low pouring temperatures and/or side as well as bottom chilling. It was found, however, that thin castings (12.5 mm) could easily be produced with a homogeneous distribution of mica particles.