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A computational model for defect prediction in shape castings based on the interaction of free surface flow, heat transfer, and solidification phenomena

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Abstract

High-integrity castings require sophisticated design and manufacturing procedures to ensure they are essentially macrodefect free. Unfortunately, an important class of such defects—macroporosity, misruns, and pipe shrinkage—are all functions of the interactions of free surface flow, heat transfer, and solidication in complex geometries. Because these defects arise as an interaction of the preceding continuum phenomena, genuinely predictive models of these defects must represent these interactions explicitly. This work describes an attempt to model the formation of macrodefects explicitly as a function of the interacting continuum phenomena in arbitrarily complex three-dimensional geometries. The computational approach exploits a compatible set of finite volume procedures extended to unstructured meshes. The implementation of the model is described together with its testing and a measure of validation. The model demonstrates the potential to predict reliably shrinkage macroporosity, misruns, and pipe shrinkage directly as a result of interactions among free-surface fluid flow, heat transfer, and solidification.

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Abbreviations

A :

1 or ∂/∂t in Table I

C :

Carmen-Kozeny constant

C p :

specific heat

D :

mold thickness

d :

characteristic “structure” or grain size dimension

f :

solid fraction

f c :

coherency point

f e :

eutectic point

F μ :

smooth switching function

g :

acceleration due to gravity

g :

gas

h :

enthalpy

K :

permeability

L :

latent heat

m :

metal

n :

normal vector

P :

pressure

P ames :

ambient pressure

P I :

initiation pressure

Q air :

air flow rate through the mold

Q v :

volume source

Q s :

surface flux source

R :

flow resistance in the mold

r :

pore radius

S :

mass sources

S v :

specific surface area

S D :

Darcy source term

T :

temperature

u :

liquid velocity

v slip :

slip velocity

ε’:

mold porosity

μ :

viscosity

ρ :

density

φ :

transported variable

σ :

surface tension

φ m :

metal fraction

Γ:

diffusion coefficient

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Authors and Affiliations

  1. the Centre for Numerical Modelling and Process Analysis, University of Greenwich, SE10 9LS, London, United Kingdom

    S. Bounds (Research Fellow), G. Moran (Research Fellow), K. Pericleous (Professor), M. Cross (Professor) & T. N. Croft (Senior Research Fellow)

Authors
  1. S. Bounds
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  2. G. Moran
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  3. K. Pericleous
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  4. M. Cross
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  5. T. N. Croft
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Bounds, S., Moran, G., Pericleous, K. et al. A computational model for defect prediction in shape castings based on the interaction of free surface flow, heat transfer, and solidification phenomena. Metall Mater Trans B 31, 515–527 (2000). https://doi.org/10.1007/s11663-000-0157-1

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