Evaluating the effects of vortex generation and the settling time of reinforcing particles on the mechanical characteristics of the PRMMC: A real-time simulation and experimental study

Particle Reinforced Metal Matrix Composite (PRMMC) has a significant impact on the various aerospace and automotive industries. This research aims to examine the reason behind the non-homogenous distribution of the reinforcement particles using numerical and real-time simulation approaches. A novel Real-Time Simulation (RTS) technique was adopted to evaluate the stirring performance of the reinforcement particles. The RTS experiments have been carried out using a transparent solution as the liquid medium and Silicon Carbide (SiC) particles as the reinforcement particles. In this research, three major parameters such as particle size (105, 63 and 44 μm), Volume fraction (5, 10 and 15 %) and stirrer blade (Flat Blade (FB), Turbine Blade (TB) and Propeller Blade (PB)) was used to analyze the vortex formation in the liquid medium and settling time of the reinforcement particles. The confirmation experiments were done using the Al-5Zn-2.3Mg-1.4Cu alloy with SiC as the reinforcement particles. Elemental mapping, Electron backscatter diffraction (EBSD) and the clustering analysis using the RTS technique support the attainment of the uniform distribution of the particles. Mechanical characterization such as tensile, hardness and wear tests were carried out. From the confirmation experiments, it was concluded that the optimal condition (particle size of 63 μm, 10 % volume fraction of SiC particles and PB stirrer) shows 18.2 % higher tensile strength and uniform hardness value of 83VHN and 32 % more wear resistance than the initial conditions (particle size of 44 μm, 15 % volume fraction of SiC particles and FB stirrer).