Efficient oscillating micro-grid mixing of CFA-aluminium composite melts

Abstract

An analytical, numerical and experimental study is presented on the deagglomeration and dispersion of fine coal fly ash (CFA) reinforcing particles in an A380 aluminium matrix using a piston-actuated oscillating micro-grid mixing method with a specially designed grid geometry. Based on real-time measurement of the piston force, the apparent viscosity of the melt and the effectiveness of the deagglomeration are measured indirectly. The oscillating micro-grid mixing process is shown to be considerably more time-efficient that comparative stir-casting processes currently employed, leading to a two-fold or three-fold reduction in processing time for the same or better mixing quality, or alternatively a nearly two-fold reduction in the standard deviation of the micro-hardness throughout the material.