Abstract
High-pressure casting (HPDC) is an increasingly important production process for large, thin-walled components. When geometries combine large thin areas with volumetric regions, defects due to misruns, cold shuts, air pockets, and porosity can occur in close proximity and influence each other. Simulation-based process optimization requires a combined modeling approach to capture these errors fully coupled. To address this task, a multi-phase fully coupled mold filling and solidification methodology has been developed. Liquid melt and gas are treated as compressible fluids separated by a sharp volume-of-fluid interface. Reduced melt flow due to solidification is achieved by a mushy-zone model. The methodology allows the simultaneous simulation of reduced melt flow, air compression, and porosity formation due to gas evaporation and volume shrinkage. The ability to address these defects with one combined modelling approach was validated by casting trials using a specially designed geometry for thin-walled aluminum HPDC applications.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
The aluminum automotive manual, version 2002 © European Aluminium Association, https://www.european-aluminium.eu/wp-content/uploads/2012/01/AAM-Manufacturing-1-Casting-methods.pdf.
Beckermann C, Monroe A (2009) Porosity Simulation for High Pressure Die Castings. Die Casting Engineer, The North American Die Casting Association, May 2009, ISSN 0012-25JX.
Bodhayana M R and Ramesha N (2014) Molten Metal Flow Analysis of Housing Component. Int. J. of Research in Engineering and Technology 03(11). ISSN 2319-1163.
Arslan F K, Hatmann A H, Ertürk S Ö, Güner E, Güner B (2012) An Evaluation for Fundamentals of Die Casting Materials Selection and Design. IMMC’16 International Metallurgy & Materials Congress, Istanbul, Turkey.
Zhu J, Yokoyama H, Ohnaka I, Murakami T, Cockcroft S L (2009) Prediction of Casting Defects in High-pressure Die Casting Processes by Using JSCAST. Modeling of Casting, Welding and Prediction of Casting Defects in Advanced Solidification Processes XI I, (Warrendale, TMS ):361–368.
Jana S, Kaettlitz O, Hediger F, Jakumeit J, Aguilar J (2012) Predictions of misruns using three-phase coupled mold-filling and solidification simulations in low pressure turbine (LPT) blades. MCWASP XIII, IOP Publishing, IOP Conf. Series: Materials Science and Engineering: 33.
Ferziger J.H. and Peric M, (ed) (2002) Computational Methods for Fluid Dynamics. McGraw-Hill. ISBN 2-540-42074-6.
Teskeredzic A, Demirdzic I, Muzaferija S (2002), Num. Heat Trans. B 42:43.
Demirdzic I, Muzaferija S (1995) Comp. Met. in App. Mech. and Eng. 125:235–255.
Muzaferija S, Peric M (ed) (1999) Mahrenholtz and M. Markiewicz, WIP Press, Southampton:59–100
Brackbill J U, Kothe D B, Zemach C (1992) J. of Computational Physics 100:335.
Sabau A S,Viswanath S (2002)Met. Mat. Trans. B 33B:131.
Poirier D R, Yeum K, Mapples A L (1987) Metall. Mater. Trans. A 18:1979.
Jakumeit J, Jana S, Waclawczyk T, Mehdizadeh A, Sadiki A, Jouani J (2012) Four-phase fully-coupled mold-filling and solidification simulation for gas porosity prediction in aluminum sand casting. MCWASP XIII, Dirac house, temple black, Bristol BS1 6BE, England.
Niyama T, Uchida M, Morika W A, Saito S (1982) Int. cast metals journal 7:52–63.
Acknowledgements
The work was supported by BMWi (Bundesministerium für Wirtschaft und Energie), INNOKOM project Fast Solid, funding contract 49VF170031, and joint project SPEED funding contract 03ET1516A. The authors acknowledge the support by Siemens PLM, agreement 60068580, for providing STAR-CCM+ licenses.
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2021 The Minerals, Metals & Materials Society
About this paper
Cite this paper
Jakumeit, J. et al. (2021). Coupled Modeling of Misrun, Cold Shut, Air Entrainment, and Porosity for High-Pressure Die Casting Applications. In: Perander, L. (eds) Light Metals 2021. The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-65396-5_114
Download citation
DOI: https://doi.org/10.1007/978-3-030-65396-5_114
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-65395-8
Online ISBN: 978-3-030-65396-5
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)