S. K. Paknikar

Abstract: Casting solidification is actually the transformation of liquid phase to solid phase with the liberation of latent heat of fusion. During this metallurgical process, it induces casting defects like shrinkage, porosity and hot tears. To eradicate and eliminate these problems, appropriate design of casting and methoding (feeding and gating system) is necessary. The problems can be predicted and prevented by means of computer simulation of casting solidification. This paper discusses the simulation of casting solidification with the aid of an example, which will help foundry engineers and industrial metallurgists in understanding the temperature history of the solidifying casting, and in identifying the hot spot region with the aid of obtained time-temperature contours. These results will be used to get defect-free as-cast products by optimising the casting design based on findings attained from the simulation process. Foundries are supported by several software simulation packages which differ in terms of functionality, user interface, cost per simulation and prediction accuracy matching the radiographic shrinkage porosity levels specified by the customer.

Keywords: Metal casting, solidification, shrinkage, simulation.