Microstructure and defects in aluminum alloy castings: Numerical prediction and experimental verification

Conference · Sun Dec 31 00:00:00 EST 1995

OSTI ID:227784

Ahmed, A; Chadwick, T; Makhlouf, M; Apelian, D ^[1]

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1. Worcester Polytechnic Inst., MA (United States)

This paper deals with the effects of various solidification variables such as cooling rate, temperature gradient, solidification rate, etc. on the microstructure and shrinkage defects in aluminum alloy (A356) castings. The effects are first predicted using commercial solidification modeling softwares and then verified experimentally. For this work, the authors are considering a rectangular bar cast in a sand mold. Simulation is performed using SIMULOR, a finite volume based casting simulation program. Microstructural variables such as dendritic arm spacing (DAS) and defects (percentage porosity) are calculated from the temperature fields, cooling rate, solidification time, etc. predicted by the computer softwares. The same variables are then calculated experimentally in the foundry. The test piece is cast in a resin (Sodium Silicate) bonded sand mold and the DAS and porosity variables are calculated using Scanning Electron Microscopy and Image Analysis. The predictions from the software are compared with the experimental results. The results are presented and critically analyzed to determine the quality of the predicted results. The usefulness of the commercial solidification modeling softwares as a tool for the foundry are also discussed.

• OSTI ID: 227784
• Report Number(s): CONF-9509118-; ISBN 0-87339-297-3; TRN: IM9622%%61
• Resource Relation: Conference: 7. Conference on modeling of casting, welding and advanced solidification processes, London (United Kingdom), 10-15 Sep 1995; Other Information: PBD: 1995; Related Information: Is Part Of Modeling of casting, welding and advanced solidification processes, 7; Cross, M. [ed.] [Univ. of Greenwich, London (United Kingdom). Centre for Numerical Modeling and Process Analysis]; Campbell, J. [ed.] [Univ. of Birmingham (United Kingdom). School of Metallurgy and Materials]; PB: 1030 p.
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
99 MATHEMATICS
COMPUTERS
INFORMATION SCIENCE
MANAGEMENT
LAW
MISCELLANEOUS
ALUMINIUM ALLOYS
MICROSTRUCTURE
MATHEMATICAL MODELS
SILICON ALLOYS
MAGNESIUM ADDITIONS
SOLIDIFICATION
LIQUID METALS
SIMULATION
FINITE DIFFERENCE METHOD
HEAT TRANSFER
TEMPERATURE GRADIENTS
PHASE TRANSFORMATIONS
SHRINKAGE
POROSITY
DENDRITES
COMPUTER CALCULATIONS
SCANNING ELECTRON MICROSCOPY
IMAGE PROCESSING
CORRELATIONS