About this Abstract |
Meeting |
2021 TMS Annual Meeting & Exhibition
|
Symposium
|
Cast Shop Technology
|
Presentation Title |
Coupled Modeling of Misrun, Could Shut, Air Entrainment and Porosity for High Pressure Die Casting Applications |
Author(s) |
Juergen Jakumeit, Herfried Behnken, Romuald Laqua, Simon Pierre Junior Mbewou, Martin Fehlbier, Julian Gänz, Leonard Becker |
On-Site Speaker (Planned) |
Juergen Jakumeit |
Abstract Scope |
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. |
Proceedings Inclusion? |
Planned: Light Metals |