Processing of aluminium and its alloy in an economical way is still a big challenge for the industry. In the present work, a novel continuous casting set-up has been designed and manufactured to introduce alloying elements, particulate reinforcement and grain refiners in any Al system by implementing mechanical force convection and bottom-feeding of elements or particles in liquid aluminium. The main objectives behind the design are to minimize capital cost, running cost, time, energy consumption and defects in the cast products. The present set-up does not lead to vortex formation during mixing to disperse the particles. Thus, there is less possibility of entrapment of gasses and hence subsequent formation of casting defects is comparatively fewer. A detailed study on the various temperature zones in the set-up has been accomplished using a data logger. The cast alloy, metal matrix composite and grain refiner added aluminium alloy were subjected to optical microscopy, scanning electron microscopy and X-ray diffraction studies. The results showed uniform distribution of reinforcement particles and alloying elements in metal matrix composite and commercial pure aluminium alloy, respectively. Grain refinement in aluminium alloy was also observed after the addition of grain refiner. A cost analysis study of the casted product showed that, the present proposed process is comparatively economical than the conventional available process.

以经济的方式加工铝及其合金仍然是该行业的一大挑战。在目前的工作中，已经设计并制造出一种新颖的连续铸造装置，以通过在机械铝的对流和液体铝中元素或颗粒的底部进料来将合金元素，颗粒增强剂和晶粒细化剂引入任何Al系统中。设计背后的主要目标是最大程度地降低投资成本，运行成本，时间，能耗和铸造产品中的缺陷。本装置在混合以分散颗粒的过程中不会导致涡流形成。因此，气体滞留的可能性较小，因此随后形成的铸造缺陷相对较少。使用数据记录器已经完成了对设置中各个温度区域的详细研究。对铸造合金，金属基复合材料和添加晶粒细化剂的铝合金进行了光学显微镜，扫描电子显微镜和X射线衍射研究。结果表明，增强颗粒和合金元素分别在金属基复合材料和商用纯铝合金中均匀分布。添加晶粒细化剂后，还观察到铝合金中的晶粒细化。对铸件的成本分析研究表明，与传统的现有工艺相比，本提议的工艺相对经济。扫描电子显微镜和X射线衍射研究。结果表明，增强颗粒和合金元素分别在金属基复合材料和商用纯铝合金中均匀分布。添加晶粒细化剂后，还观察到铝合金中的晶粒细化。对铸件的成本分析研究表明，与传统的现有工艺相比，本提议的工艺相对经济。扫描电子显微镜和X射线衍射研究。结果表明，增强颗粒和合金元素分别在金属基复合材料和商用纯铝合金中均匀分布。添加晶粒细化剂后，还观察到铝合金中的晶粒细化。对铸件的成本分析研究表明，与传统的现有工艺相比，本提议的工艺相对经济。