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Casting Simulation and Cavity Analysis

This chapter discusses the requirements for simulating the casting of an aluminum alloy ingot in a sand mold to locate shrinkage cavities using solidification contours. It describes experimenting with casting a 1kg aluminum (LM13) ingot with dimensions of 30x40x40cm in a sand mold using a gas furnace, thermocouple, and degassing the melt before pouring at 610°C. After solidification, the mold was broken and the ingot was sectioned longitudinally and perpendicular to identify the cavities.

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4 views3 pages

Casting Simulation and Cavity Analysis

This chapter discusses the requirements for simulating the casting of an aluminum alloy ingot in a sand mold to locate shrinkage cavities using solidification contours. It describes experimenting with casting a 1kg aluminum (LM13) ingot with dimensions of 30x40x40cm in a sand mold using a gas furnace, thermocouple, and degassing the melt before pouring at 610°C. After solidification, the mold was broken and the ingot was sectioned longitudinally and perpendicular to identify the cavities.

Uploaded by

hayder1920
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Experimenting, Numerical Modeling, and Programming

3.1 Introduction
This chapter deals with the necessary requirements of casting simulation of the
studied ingot in a sand mold, which is performed to allocate the shrinkage cavities using
the solidification contours. Also, it deals with the real casting of this ingot with the
same conditions to verify this method of cavity identification by simulation.
3.2 Experimentation
3.2.1 Materials and instruments
The materials, tools and instruments which are used in the present work are:
1- One kilogram of Aluminum alloy of type LM13 with a standard chemical
composition contained in table (3.1) [41].
2- An alumina crucible.
3- A wood pattern of the ingot with dimensions as shown in figure (3.1)
4- A sand mold with a dimensions (30 40 40 cm).
5- A gas furnace for melting, (figure 3.2)
6- Degasser of type (C2Cl6), for the melt degassing.
7- K-type thermocouple with a digital thermometer.

Table (3.1). Chemical composition (mass %)

3.2.2 Casting procedure


The melting procedure of the alloy was accomplished by using the gas furnace

(fig.3.2). After the molten alloy reaches ( 620 C) it was degassed, then the crucible

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Figure 3.1. Dimensions of the ingot in (cm)

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is removed from the furnace, and preparing for pouring at ( 610 C). The temperature
control was achieved by using the thermocouple.
3.2.3Cavities Localization
After the solidification is completed, the sand mold is broken, and the ingot (fig.
3.3) was left to cool. Then it was sectioned longitudinally through the two
perpendicular mid planes. Then other sections were done to precisely identify the
cavities extension. Figures (3.4 and 3.5) show the sample sections, and the cavities.

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