Effect of in-situ processing parameters on microstructure and mechanical properties of TiC particulate reinforced Al-4.5Cu alloy MMC fabricated by stir-casting technique - Optimization using grey based differential evolution algorithm

Fabrication of metal matrix composite materials by using the traditional casting process is a very promising task of developing near net shape products at a very low cost. Among these casting processes, the stir-casting technique has fine microstructures because of fast cooling, less porosity and good quality bonding among particle and the base matrix alloy. The major aim of this present paper is to fabricate titanium carbide reinforced metal matrix composite (MMC) by using micron sized activated charcoal powder, to get react with titanium material for producing TiC intermetallic particles in the Al-4.5%Cu matrix by in-situ technique so as to produce Al-4.5%Cu-5%TiC MMC, with the intention of finding the optimum processing parameter i.e. pouring temperature, stirring speed in liquid melt-stirring process, reaction time with the aim of achieving better microstructure and mechanical properties, i.e. micro-hardness, toughness and ultimate tensile strength by using an efficient grey based differential evolution algorithm. Mechanical properties of optimum processing condition are verified by doing confirmation tests. ANOVA analysis is performed to analyze the role of each factor on multiple performance characteristics and it was found that stirrer rotational speed and reaction time is playing a key role in affecting the mechanical property. Additionally, to predict the response parameters regression equations were developed and the validity of regression model is tested by plotting scatter diagram. Finally microstructure study has been performed for the optimal sample by using optical microscope.