On the Efficient Particle Dispersion and Transfer in the Fabrication of SiC-Particle-Reinforced Aluminum Matrix Composite

Abstract

Lightweight SiC-particle-reinforced aluminum composites have the potential to replace cast iron in brake discs, especially for electric vehicles. This study investigates the effect of SiC particle size and matrix alloy composition on the resulting transfer efficiency and particle distribution. The performance of a specially designed stirring head was studied using a water model, and the stirring head conditions were assessed to understand the particle transfer and dispersion mechanisms in the molten aluminum. The standard practice of thermal pre-treatment promotes the wetting of the reinforcing particles and commonly causes clustering before the addition to the melt. This early clustering affects the transfer efficiency and particle dispersion, where their interaction with the melt top-surface oxide skin plays an important role. In addition, the transfer efficiency was linked to the particle size and the chemical composition of the matrix alloy. Smaller particles aggravated the degree of clustering, and the addition of rare earth elements as alloying elements in the matrix alloy affected the particle dispersion. The stirring parameters should be selected to ensure cluster disruption when the carbides are added to the melt.