About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
Melt Processing, Casting and Recycling
|
| Presentation Title |
Baffle-Based Sedimentation Strategies for Inclusions in Launders of Aerospace Aluminium Casting: A Sustainable Approach |
| Author(s) |
Tharmalingam (Siva) Sivarupan, Konstantinos Georgarakis, John Forde, Joseph Rawding, Ben Shaw, Arul Mozhi Varman Jayaraman Palanivel, Konstantinos Salonitis, Mark Jolly |
| On-Site Speaker (Planned) |
Tharmalingam (Siva) Sivarupan |
| Abstract Scope |
The presence of non-metallic inclusions, such as alumina, in aerospace aluminium alloy castings significantly limits the potential mechanical properties. Building on previous simulation studies (TMS 2024) that focused on the melt flowrate, the current study explores optimised launder designs using strategically placed baffles to promote effective sedimentation of these non-metallic inclusions. Utilising high-resolution CFD simulations in Flow3D, the influence of baffle angle (0°, 15°, 30°, 45°, 90°), configuration (single/ double), and placement (middle / near-inlet) on flow behaviour and inclusion settling efficiency has been evaluated. Baffles angled at 15° significantly reduce turbulence and create near stagnation-velocity zones ideal for inclusion growth and sedimentation; AlTiB master alloy promotes intermetallic growth on pre-existing alumina bifilms. Double baffle setups, one towards the launder inlet and another at the centre, outperformed single baffles in enhancing inclusion sedimentation without disrupting flow continuity. The configuration redirects convective flow, increasing inclusion residence time and promoting downward migration. |
| Proceedings Inclusion? |
Planned: Light Metals |
| Keywords |
Aluminum, Recycling and Secondary Recovery, Modeling and Simulation |