Bauxite residue (BR) is the hazardous waste produced during extraction of alumina by processing of bauxite ore. BR has an adverse effect on humans and the environment due to its disposable problem. To minimize the environmental impact, BR must be effectively utilized. One such way is to use BR as a reinforcing for metal matrix composite. In this study, Taguchi’s mixed fractional factorial experimentation (L18) approach is employed in the development of Al6063/BR composite through advanced stir casting process. The process parameters considered are stirring speed (rpm), reinforcement particle size (µm), reinforcement weight fraction (wt%) by weight of the matrix phase, pouring temperature (°C), and preheat temperature (°C). Later, ANOVA results indicate that particle percentage (wt%) is the major contributor in the development of porosity content. Moreover, the interaction of process parameters was also found to have an impact on porosity content. The outcome of the study reveals that the stirring intensity at 350 rpm, particle size at 80 µm, particle percentage at 2 wt%, pouring temperature at 730 °C, and preheat reinforcement temperature at 450 °C are the optimal conditions for fabricating defect free Al6063/BR composite.

铝土矿残留物（BR）是铝土矿矿石在氧化铝提取过程中产生的有害废物。由于其一次性使用问题，BR对人类和环境有不利影响。为了最大程度地减少对环境的影响，必须有效利用BR。一种这样的方法是使用BR作为金属基复合材料的增强材料。在这项研究中，田口的混合分数阶乘实验（L18）方法用于通过先进的搅拌铸造工艺开发Al6063 / BR复合材料。所考虑的工艺参数为搅拌速度（rpm），增强颗粒尺寸（µm），增强相重量分数（wt％）（按基体相重量计），浇注温度（°C）和预热温度（°C）。后来，方差分析结果表明，颗粒百分比（wt％）是孔隙率含量增加的主要因素。而且，还发现工艺参数的相互作用对孔隙率含量有影响。研究结果表明，以350 rpm的搅拌强度，80 µm的颗粒尺寸，2 wt％的颗粒百分比，730°C的浇铸温度和450°C的预热增强温度是制造无缺陷的最佳条件。 Al6063 / BR复合材料。