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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

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

Bounds, S., Moran, G., Pericleous, K. ORCID: 0000-0002-7426-9999, Cross, M. and Croft, T.N. (2000) A computational model for defect prediction in shape castings based on the interaction of free surface flow, heat transfer, and solidification phenomena. Metallurgical and Materials Transactions B, 31 (3). pp. 515-527. ISSN 1073-5623 (Print), 1543-1916 (Online) (doi:10.1007/s11663-000-0157-1)

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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.

Item Type: Article
Uncontrolled Keywords: casting defects, multi-physics modelling, alloy solidification
Subjects: Q Science > QA Mathematics > QA76 Computer software
T Technology > TN Mining engineering. Metallurgy
Pre-2014 Departments: School of Computing & Mathematical Sciences
School of Computing & Mathematical Sciences > Centre for Numerical Modelling & Process Analysis
School of Computing & Mathematical Sciences > Centre for Numerical Modelling & Process Analysis > Computational Science & Engineering Group
School of Computing & Mathematical Sciences > Department of Computer Systems Technology
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Last Modified: 14 Oct 2016 09:00
Selected for GREAT 2016: None
Selected for GREAT 2017: None
Selected for GREAT 2018: None
URI: http://gala.gre.ac.uk/id/eprint/415

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