Modelling of defects in aluminium cast products

Jolly, Mark; Katgerman, L.

doi:10.1016/j.pmatsci.2021.100824

Cited by 45 publications

(16 citation statements)

References 159 publications

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“…Porosity is a common defect in casting that results in air pockets or voids within the casting. Porosity can be caused by a variety of factors, including mold materials, casting temperature, and turbulence during casting (19). Remedies for porosity include using high-quality mold materials, maintaining proper casting temperature, and minimizing turbulence during casting.…”

Section: Literature Reviewmentioning

confidence: 99%

Investigating the causes and remedies for porosity defects in the casting process: A review

Sahoo¹,

Goswami²

2023

BIJE

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The casting process is a crucial manufacturing method utilized in numerous sectors to create intricate components and forms. However, there are a number of underlying causes of casting flaws that can result in subpar quality, higher costs, and decreased productivity. This review seeks to give a general overview of casting process flaws, their causes, and possible fixes. The evaluation will go over the various possible flaws, including porosity, shrinkage, and surface abnormalities, as well as their underlying causes, which include design, material, and process characteristics. Furthermore, the review will focus on various remedial measures that can be taken to overcome these defects and improve casting quality, such as changes in design, material selection, and process optimization. This review will be useful for researchers and practitioners in the casting industry who are interested in improving their understanding of casting defects and developing effective remedial measures to enhance product quality and efficiency.

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Section: Literature Reviewmentioning

confidence: 99%

Investigating the causes and remedies for porosity defects in the casting process: A review

Sahoo¹,

Goswami²

2023

BIJE

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“…Nowadays, DC casting is also widely used for producing magnesium alloy billets for its higher productivity, excellent surface quality, refined solidification structure and so on (Hatić et al , 2018a). However, there are still some problems in the production of large-size magnesium alloy billets by using traditional DC casting since structure difference, crack tendency, shrinkage cavity, severe macrosegregation and other defects become more serious as compared to smaller size billets (Jolly and Katgerman, 2022). Different from other defects that can be completely prevented or largely improved by adjusting casting technological parameters or subsequent process, macrosegregation is inevitable in casting billet and almost cannot be eliminated effectively in subsequent process (Nadella et al , 2008).…”

Section: Introductionmentioning

confidence: 99%

Predicting the effect of different magnetic fields on the solute segregation during direct chill casting of large-size magnesium alloy slab

Duan

Yang

Liu

et al. 2023

HFF

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Purpose The purpose of this paper is to reveal the solute segregation behavior in the molten and solidified regions during direct chill (DC) casting of a large-size magnesium alloy slab under no magnetic field (NMF), harmonic magnetic field (HMF), pulsed magnetic field (PMF) and two types of out-of-phase pulsed magnetic field (OPMF). Design/methodology/approach A 3-D multiphysical coupling mathematical model is used to evaluate the corresponding physical fields. The coupling issue is addressed using the method of separating step and result inheritance. Findings The results suggest that the solute deficiency tends to occur in the central part, while the solute-enriched area appears near the fillet in the molten and solidified regions. Applying magnetic field could greatly homogenize the solute field in the two-phase region. The variance of relative segregation level in the solidified cross-section under NMF is 38.1%, while it is 21.9%, 18.6%, 16.4% and 12.4% under OPMF2 (the current phase in the upper coil is ahead of the lower coil), HMF, PMF and OPMF1 (the current phase in the upper coil lags behind the lower coil), respectively, indicating that OPMF1 is more effective to reduce the macrosegregation level. Originality/value There are few reports on the solute segregation degree in rectangle slab under magnetic field, especially for magnesium alloy slab. This paper can act a reference to make clear the solute transport behavior and help reduce the macrosegregation level during DC casting.

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“…The fatigue life of aluminium castings is strongly related to the solidification conditions and the structural quality of the material [1]. There is thus a strong focus in the literature on understanding the intrinsic and extrinsic effects in cast aluminium alloys [2], and extensive work has been made in the modelling of defects [3] and to understand and predict the impact of porosities on mechanical properties and fatigue life [4][5][6][7]. However, at an early design stage, where only a preliminary geometry and type of casting process are known, an attempt to precisely predict the distribution and morphology of porosities and many other defects is an impossible task.…”

Section: Introductionmentioning

confidence: 99%

Integrated fatigue life predictions of aluminium castings using simulated local microstructure and defects

Olofsson

2023

IOP Conf. Ser.: Mater. Sci. Eng.

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In this work, an integrated simulation approach previously developed for static FE analyses is extended to microstructure- and defect-based fatigue life assessments of castings. The approach, the closed chain of simulations for cast components, combines casting process simulation with microstructure modelling and local material characterisation to generate heterogeneous material data for FE analysis and fatigue life assessment. The method is demonstrated on a High-Pressure Die Cast aluminium component. Areas with a high risk of defects are identified based on the simulated solidification conditions, and heterogeneous material data for the fatigue life analysis is generated. Fatigue testing has been performed with different levels of porosities to quantify the effect of defects on the element-specific Wöhler curves. Pore characteristics are assessed using 2D X-ray, fracture surface analysis and Kitagawa diagram. The results highlight the importance of taking the risk of defect formation into consideration when designing industrial aluminium castings subjected to fatigue loads.

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Modelling of defects in aluminium cast products

Cited by 45 publications

References 159 publications

Investigating the causes and remedies for porosity defects in the casting process: A review

Investigating the causes and remedies for porosity defects in the casting process: A review

Predicting the effect of different magnetic fields on the solute segregation during direct chill casting of large-size magnesium alloy slab

Integrated fatigue life predictions of aluminium castings using simulated local microstructure and defects

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