Solidification processing of Al-Al2O3 composite using turbine stirrer

Solidification processing of Al-Al₂O₃ composites involves mixing of nonwetting alumina particles in molten aluminum alloy resulting in a slurry where the particles are often attached to bubbles sucked at the center of vortex below the stirrer. The internal surface of bubbles is eventually oxidized by oxygen from air entrapped in it. These bubble-particle combines may float or settle during casting depending on the overall density influencing the particle and porosity distribution in a cast composite ingot where the performance of a stirrer may be evaluated under a given condition of processing. Particle incorporation is more for turbine stirrers instead of flat blade stirrers, but the porosity also increases. Flotation of bubble-particle combines during casting of ingot results in higher particle content at the top. Microstructure shows clusters of particles along circular boundaries of thin oxides at the top of the ingot and sometimes at the bottom. This may be a consequence of filling of bubbles to different extents by surrounding liquid puncturing the oxide layer, if necessary, during solidification. When the manner of stirring is changed to 2 minutes of stirring of particles into molten alloy with an intermediate 2-minute period of no stirring before stirring the slurry again for 2 minutes, relatively uniform particle incorporation results along the height of cast ingot compared to that obtained by continuous stirring. This difference in particle distribution may be attributed to flotation of bubble-particle combines to release the particles on the top of the slurry when stirring ceases and its remixing into the slurry when it is stirred again. However, an increase in the intermediate period of no stirring and a higher processing temperature result in enhanced porosity and a more inhomogeneous particle distribution along the height of the ingot.