Optimization of setting parameters for aluminium matrix composite reinforced with boron carbide using two-stage stir casting techniques

Stir casting is a widely used metallurgical technique for producing aluminum matrix composites. Many studies in this area have focused on fabricating these composites using fixed stir casting parameters, often overlooking the importance of an optimization approach. These parameters significantly influence the microstructure and overall performance of the composites. This investigation aims to refine stir-casting parameters to produce Al 6061 composites reinforced with B4C microparticles, thereby improving their performance. The sample was prepared using the two-step stir-casting technique with a 2 wt% B4C particle composition. The Taguchi method was utilized to optimize three critical parameters in stir casting, such as melting temperature (700-800 ºC), stirring speed (100-300 rpm), and stirring time (10-30 minutes), which were systematically adjusted. A systematic analysis using an L9 orthogonal array was conducted to determine how varying levels of process parameters affected hardness properties. The optimization of two-stage stirs casting parameters using the Taguchi method identified stirring speed as the most dominant factor, with an optimal combination of 700 ºC melting temperature, 200 rpm stirring speed, and 20 min stirring time producing the highest Brinell hardness in Al 6061–2 wt.% B₄C composites. Analysis of variance results indicated that all three stir casting parameters significantly influenced the property responses, with stirring speed being the most dominant factor in achieving the highest Brinell hardness (HB) in the composite material.