Filling, Feeding and Defect Formation of Thick-Walled AlSi7Mg0.3 Semi-Solid Castings

Modeling of Reoxidation Inclusion Formation During Filling of Steel Castings

A reoxidation inclusion model is described that simulates the entire life cycle of inclusions during the filling of steel castings and predicts their final location in the casting. Inclusions can be released into the mold at the inlet and/or nucleate on the metal free surface, where contact with oxygen from the atmosphere creates them. Inclusion motion is calculated by solving an equation of mo...

Al-7Si-Mg Semi-Solid Castings – Microstructure and Mechanical Properties

Feeding of High-Nickel Alloy Castings

Feeding of the nickel-based alloys CZ-100, M-35-1, and CW-12MW, as well as of the austenitic stainless steel CN-7M, is investigated, using a combination of casting experiments and simulation. Casting trials are performed at five foundries, to produce a total of 55 plates of varying lengths and radiographic soundness levels. In order to develop the property databases necessary to simulate the ca...

Mechanism of Filling and Feeding of Thin-Walled Structures during Gravity Casting

The filling and feeding of thin-walled structures in metal castings pose significant difficulties in manufacturing aerospace structural materials. Samples containing 2 mm and 5 mm thin-walled structures were designed to study the kinetics of filling. The microstructural evolution of the solidification of thin-walled structures was studied with synchrotron X-radiation imaging. The formation of d...

Undercooling and nodule count in thin walled ductile iron castings