ProCAST General Presentation 2
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Typical Defects Predictions
Validations
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Density of metals
vs. temperature is
not constant:
Density, Kg/m3
Predicting Solidification Defect in
Al HPDC– Shrinkage Porosity
Temperature, °C
Feeding problems
during solidification:
Courtesy of Kovolit, CZ
Al HPDC
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Predicting Solidification Defect in
Cast Iron Sand Gravity– Cold Shot
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Predicting Filling Defect in
Zn HPDC–Die Erosion
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Predicting Filling in
Zn HPDC–Interrupted shot
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Predicting Filling in
Zn HPDC–Interrupted shot
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Predicting Filling in
Zn HPDC–Interrupted shot
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Predicting Filling in
Al Sand Casting-Coldshut prediction
Vacuum forming
Aluminium
Silica Dry
t = 2 mm
h = 400 mm
d = 100 mm
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Filling Validation
Arbeitsgemeinschaft, Metallguss, Aalen (D)
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Filling Validation
Incomplete filling
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Filling Validation
Cold Shut
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Filling Validation
Thixocasting validation
Sophia Antipolis, Collot
Magnesium alloy (AZ91):
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Filling Validation
Thixocasting validation
Courtesy of Alusuisse
Aluminium alloy (A356)
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Filling Validation
Thixocasting validation
Aluminium alloy (A356)
Courtesy of Austrian Research Centre
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Microstructure Validation
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Case Study 1
AL HPDC
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« Standard » Casting Simulation
GEOMETRY
PROCESS
MATERIAL
THERMAL & FLUID
ANALYSIS
THERMODYNAMIC
DATABASES
THERMO PHYSICAL
PROPERTIES
DEFECTS
•FILLING DEFECTS
•SOLIDIFICATION DEFECTS
However, Shrinkage Porosity and Improper Fills are
Important Defects predicted with Thermal And Fluid
Analysis, but They Aren’t the Only Defects in
Casting Processes…
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“Cylinder” Model – NADCA Benchmark
HPDC process / A383 Alloy
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Guideline: Casting Modelling Phases
Phase 1 : Thermal cycling
Phase 2 : Filling (with extraction of thermal map at the end of cycling)
Phase 3 : Solidification (coupled with filling)
Phase 4 : Shrinkage and gas porosity
Phase 5 : Stress (coupled with filling and solidification)
Phase 6 : Microstructure and Mechanical Prop.
Copyright © ESI Group, 2007. All rights reserved.
Casting Modelling Phases
Phase 1 : Thermal cycling
Phase 2 : Filling (with extraction of thermal map at the end of cycling)
Phase 3 : Solidification (coupled with filling)
Phase 4 : Shrinkage and gas porosity
Phase 5 : Stress (coupled with filling and solidification)
Phase 6 : Microstructure and Mechanical Prop.
Copyright © ESI Group, 2007. All rights reserved.
Heat Up Cycles
15 Cycles Performed to
Ensure Die Soak (Cavity
Region Soaked in About 9,
When Starting at 200 F)
Regions Which Stay Warm
are Indicated.
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Casting Modelling Phases
Phase 1 : Thermal cycling
Phase 2 : Filling (with extraction of thermal map at the end of cycling)
Phase 3 : Solidification (coupled with filling)
Phase 4 : Shrinkage and gas porosity
Phase 5 : Stress (coupled with filling and solidification)
Phase 6 : Microstructure and Mechanical Prop.
Copyright © ESI Group, 2007. All rights reserved.
OPTIMIZATION OF
PISTON VELOCITY PROFILE
140
Two Shot Profiles Provided:
0.42m/s Slow Shot to 3 m/s
Fast Shot
0.23m/s Slow Shot to 3 m/s
Fast Shot
Plunger Speed (ips)
120
100
80
60
40
20
0
0
0.2
0.4
0.6
Time (s)
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0.8
1
Air Entrapment
Air Trapped In Sleeve
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Filling
MODELING MISRUNS, OXIDES,
TURBULENCES, AIR ENTRAPMENT,
VENTING POSITIONING…
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