Optimization of process variables and characterization of mechanically agitated ceramic‐microsphere reinforced aluminium composite

Abstract This study aims to investigate the effect of stir‐casting process parameters, including stirring speed, stirring time, and weight % of the ceramic microsphere, on the fabrication of an aluminium 6061‐ceramic microsphere composite. Experiments are conducted using a full‐factorial design approach to determine the effect of variables on mechanical properties. A field effect scanning electron microscope is used to analyze the fracture surfaces of the test specimen. Further, the results are subjected to the Anderson‐darling normality test to validate the accuracy of the model, and finally, an analysis of variance is performed to identify the most significant parameters that affect the mechanical properties. The results confirm the validity of the designed experimental model for enhancing the mechanical properties of the aluminium 6061‐ceramic microsphere composite. The optimum mechanical properties are attained for a stirring speed of 600 min −1 , stirring time of 15 min, and 5 weight % of reinforcement. Furthermore, the weight percentage of the ceramic microsphere increase, the ductility of the composite decreases while its strength and hardness increase. Finally, the analysis of variance shows that all parameters significantly impact the mechanical properties of the designed composite.