Optimization of SiC particle distribution during compocasting of A356-SiCp composites using D-optimal experiment design

This paper presents an experimental design approach to the process parameter optimization for compocasting of A356-SiCp composites. Toward this end, parameters of stirring temperature, stirring time, stirring speed and SiC content were chosen and three levels of these parameters were considered. The D-optimal design of experiment (DODE) was employed for experimental design and analysis of results. In the experimental stage, different 20 µm-sized SiC particle contents (5, 10 and 15 vol %) were introduced into semisolid-state A356 aluminium alloy. Semisolid stirring was carried out at temperatures of 590, 600 and 610 °C with stirring speeds of 200, 400 and 600 rpm for 10, 20 and 30 min. The effect of these parameters on the distribution of the SiC particles within the matrix, represented by distribution factor (DF), was investigated. The smaller value of DF is indicative of the more uniform distribution of the SiC particles in the matrix. It was observed that the SiC particle content of 15 vol %, stirring temperature of 590 °C, stirring speed of 500 rpm, and stirring time of 30 min were the optimum parameter values producing the best distribution of the SiC particles in the matrix. The statistical test revealed that the main effect of the stirring temperature is the most significant factor.