Casting process modeling using ProCAST and CAST2D -- Mold filling, solidification and structural response

Technical Report · Wed Apr 01 04:00:00 EST 1992

OSTI ID:5655226

Stein, W; Shapiro, A B

Correctly modeling the fluid flow and heat transfer during the filling of a mold with a molten fluid is important in predicting the quality of a cast part. Determining the dynamics of the flow and the free surface shape during filling are essential in establishing the temperature gradients in the melt and in the mold. After filling the mold, solidification may be greatly affected by natural convection effects. Further, correctly modeling the physics across the solidifying part-mold interface is crucial in predicting the part final shape. Most metals undergo a volume change on solidification (e.g. aluminum-6.6%) and shrinkage on cooling. As the cast metal shrinks, it pulls away from the mold wall creating a gap. This gap affects the thermal contact resistance between the part and mold. The thermal contact resistance increases as the gap widens. This directly affects the cooling rate and ultimately the final cast shape, stress state, and quality of the cast part.

• Research Organization: Lawrence Livermore National Lab., CA (United States)
• Sponsoring Organization: DOE; USDOE, Washington, DC (United States)
• DOE Contract Number: W-7405-ENG-48
• OSTI ID: 5655226
• Report Number(s): UCRL-ID-110428; ON: DE92013262
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
360101* -- Metals & Alloys-- Preparation & Fabrication
99 GENERAL AND MISCELLANEOUS
990200 -- Mathematics & Computers
ALUMINIUM
C CODES
CASTING
CASTING MOLDS
COMPUTER CODES
CONVECTION
DIFFERENTIAL EQUATIONS
ELEMENTS
ENERGY TRANSFER
EQUATIONS
FABRICATION
FINITE ELEMENT METHOD
FLUID FLOW
HEAT TRANSFER
MASS TRANSFER
MATHEMATICAL MODELS
METALS
NATURAL CONVECTION
NAVIER-STOKES EQUATIONS
NUMERICAL SOLUTION
P CODES
PARTIAL DIFFERENTIAL EQUATIONS
PHASE TRANSFORMATIONS
SOLIDIFICATION