Journal of Applied & Computational Mathematics

Casting Simulation and Prediction of Shrinkage Cavities

Abstract

Jabur AS and Kushnaw FM

This work aims to predict the shrinkage defects in Al-Si castings by determination the suitable parameters and techniques which can be applied in the casting simulation system. Also, it aims to specify the role of silicon content in amount, morphology, and distribution of these defects. The Numerical solution has been carried out using an explicit 3-D finite difference method for the given system of the casting and a mold. Additionally, an experimental casting of the studied samples was achieved. It was found that the shrinkage porosities increased with increasing the silicon content up to 7%, so at this peak, they spread in all cast regions and cannot be predicted. The low silicon alloys suffered from only the cavities defects that can be predicted by mapping the solidus time contours. Finally, it was concluded that the critical temperature gradient value of the porosities development in the eutectic (Al-12%Si) alloys was 1.3°C/cm.