2.
Preparation of Aluminium Alloy Specimen by Stir Casting Technique
Objective:
To prepare an aluminum alloy specimen using the stir casting technique and to study its
microstructure and properties.
Materials Required:
1. Aluminium (base metal)
2. Alloying elements (e.g., magnesium, silicon, etc.)
3. Crucible
4. Furnace
5. Stirring setup (motorized stirrer with variable speed)
6. Molds (metallic or sand)
7. Thermocouples
8. Safety equipment (gloves, goggles, apron, etc.)
Apparatus:
1. Stir casting setup (furnace and stirrer)
2. Weighing balance
3. Tongs
4. Muffle furnace (optional)
5. Cooling setup (water- or air-cooling system)
6. Metallurgical microscope (for microstructure study)
Theory:
Stir casting is a liquid-state method of composite material fabrication. This process involves
melting the base material (aluminum) and adding the reinforcement (alloying elements) into
the molten metal with mechanical stirring. This ensures a uniform distribution of the
reinforcement and enhances the material's properties.
Steps in Stir Casting:
1. Melting: Aluminium is melted in a furnace at a temperature above its melting point
(~660°C).
2. Addition of Alloying Elements: Pre-weighed alloying elements are added to the
molten aluminum.
3. Stirring: The mixture is stirred mechanically at a controlled speed (e.g., 300–500
rpm) to ensure homogeneous mixing.
4. Degassing: The melt is degassed using a suitable method (e.g., argon gas) to remove
dissolved gases.
5. Pouring: The molten mixture is poured into preheated moulds to solidify.
6. Cooling and Solidification: The cast is cooled, either naturally or using a cooling
system, to form the final alloy.
Procedure:
1. Preparation:
a. Set up the stir casting apparatus and ensure all components are in working
condition.
b. Preheat the mold to remove moisture and ensure smooth casting.
2. Melting:
a. Weigh the aluminium and alloying elements as per the composition.
b. Load the aluminum into the crucible and place it in the furnace. Heat until fully
molten.
3. Addition of Alloying Elements:
a. Add the alloying elements gradually while maintaining the furnace temperature.
b. Stir the molten mixture at a constant speed using the stirrer.
4. Degassing:
a. Introduce argon or another suitable gas into the melt to remove impurities.
5. Pouring and Solidification:
a. Pour the molten alloy into the preheated mold.
b. Allow the alloy to solidify in the mold.
6. Post-processing:
a. Remove the cast specimen from the mold.
b. Perform any necessary cleaning or surface finishing.
Observations:
1. Record the melting temperature and stirring time.
2. Note the composition of the alloy and its distribution.
3. Measure the cooling time and note the solidification characteristics.
Precautions:
1. Wear proper safety gear to avoid burns or injuries.
2. Ensure the furnace and stirring setup are handled carefully.
3. Preheat the mold to prevent defects in casting.
4. Maintain a consistent stirring speed to avoid segregation of elements.
Result:
A uniform aluminum alloy specimen is prepared successfully using the stir casting technique.
The microstructure is observed to confirm the distribution of alloying elements.