MAGMASOFT Simulation of Sand Casting Process With EV31A Magnesium Alloy

Abstract

Magnesium alloys with rare earth (RE) elements addition, modified with zirconium are used for cast, light-weight solutions for components applied at temperature up to 250–300 °C. Computational methods are often used by the foundries to decrease the cost of a new product start-up. The commercially available magmasoft software is widely used to simulate a casting process. Nevertheless, its database does not contain complete data for modern alloys. We present the results of our investigations on the thermo-physical properties of a EV31A magnesium alloy and the simulation of a sand casting process with applied data. We compared the simulation and technological trials, recognized problems occurring during the simulation, and applied corrections. Our final simulations gave acceptable results. The differences between the technological tests and the simulation were caused by factors that are difficult to model in the simulation, such as the presence of nonmetallic inclusions and the degree of modification of the liquid alloy.

Application of Computer Simulation in EV31A Magnesium Alloy Casting Process Using MAGMASoft Software

“…A set of simulation input parameters, including density, specific heat and thermal conductivity in the funticon of temperature, as well as liquidus and solidus temperatures has been measured and presented in the previous work by Jarosz, Kiełbus and Dybowski [14]. The commercial engine inlet body have been sand casted using commercial EV31A alloy under the inert atmosphere of Ar (6 dm 3 /min), CO2 (6 dm 3 /min) and SF6 (0.16 dm 3 /min).…”

Three-Dimensional Modeling of Segregation Behavior during Solidification of a Sn-6 wt.% Pb Alloy

“…For industrial mass production, sand-mold casting is often used [8][9][10], and putting chills at specific locations to accelerate cooling is common. Castings with intricate structures [8] such as engine housings, pump housings and pistons are typically sand-cast [9], sometimes with chills inserted.…”

“…For industrial mass production, sand-mold casting is often used [8][9][10], and putting chills at specific locations to accelerate cooling is common. Castings with intricate structures [8] such as engine housings, pump housings and pistons are typically sand-cast [9], sometimes with chills inserted. Owing to their complex geometry and three-dimensional nature, exploring the relationship between processing parameters and macrosegregation based only on experiments is expensive and time-consuming.…”