The modelling of oxide film entrainment in casting systems using computational modelling

Reilly, Carl; Green, N. R.; Jolly, Mark; Gebelin, Jean‐Christophe

doi:10.1016/j.apm.2013.03.061

Cited by 21 publications

(14 citation statements)

References 16 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…This critical value can be applied in the numerical model for simulating entrainment process of bifilm defect as two streams, (e.g., the reverse eddy and the jet in Figure 16) are joined. [19,20] …”

Section: ½5mentioning

confidence: 98%

Bifilm Defect Formation in Hydraulic Jump of Liquid Aluminum

Hsu

2016

Metall Mater Trans B

View full text Add to dashboard Cite

In aluminum gravity casting, as liquid aluminum fell through a vertical sprue and impacted on the horizontal flat surface, a phenomenon known as hydraulic jump (i.e., flow transition from super-critical to sub-critical flows) was observed. As the jump was transformed, a reverse eddy motion on the surface of the jump was created. This motion entrained aluminum oxide film from the surface into aluminum melt. This folded film (so-called ''bifilm'' defect) was engulfed by the melt and caused its quality to deteriorate. To understand this phenomenon, aluminum casting experiments and computational modeling were conducted. In the casting experiment, a radius (R j ) to the point where the circular hydraulic jump occurred was measured. This is the circular region of 'irregular surface feature', a rough oxidized surface texture near the center area of the castings. To quantify contents of the bifilm defects in the outer region of the jump, the samples in this region were sectioned and re-melted for doing re-melted reduced pressure test (re-melt RPT). An ''area-normalized'' bifilm index map was plotted to analyze bifilms' population in the samples. The flow transition in the hydraulic jump of liquid aluminum depended on three pressure heads: inertial, gravitational, and surface-tension pressures. A new theoretical equation containing surface tension for describing the flow transition of liquid metal was proposed.

show abstract

Section: ½5mentioning

confidence: 98%

Bifilm Defect Formation in Hydraulic Jump of Liquid Aluminum

Hsu

2016

Metall Mater Trans B

View full text Add to dashboard Cite

show abstract

“…The evolution of numerical models has also contributed towards the accurate prediction of casting defects using CFD simulations. More specifically, CFD has been implemented for the prediction of double oxide film defects [12], macroshrinkage [13] and microporosity [14]. According to Ravi [15], CFD has been proven to be particularly useful for 3 main purposes: (a) quality enhancement of final casting components [16], (b) yield improvement by reducing the mass of the feeding and gating channels [17] and (c) rapid development of new casting designs by reducing the number of foundry trials [18].…”

Section: Introductionmentioning

confidence: 99%

A Computational Framework Towards Energy Efficient Casting Processes

Papanikolaou

Pagone

Salonitis

et al. 2018

Sustainable Design and Manufacturing 2018

View full text Add to dashboard Cite

Casting is one of the most widely used, challenging and energy intensive manufacturing processes. Due to the complex engineering problems associated with casting, foundry engineers are mainly concerned with the quality of the final casting component. Consequently, energy efficiency is often disregarded and huge amounts of energy are wasted in favor of high quality casting parts. In this paper, a novel computational framework for the constrained minimization of the pouring temperature is presented and applied on the Constrained Rapid Induction Melting Single Shot Up-Casting (CRIMSON) process. Minimizing the value of the pouring temperature can lead to significant energy savings during the melting and holding processes as well as to higher yield rate due to the resulting reduction of the solidification time. Moreover, a multi-objective optimization component has been integrated into our scheme to assist decision makers with estimating the trade-off between process parameters.

show abstract

“…CFD has been extensively used in metal casting and simulating the flow of molten metals in moulds. [3][4][5][6] Reilly et al 7,8 have critically reviewed the role of CFD in defect entrainment in the shape casting process and summarized different numerical approaches used in different commercial packages, that is, MAGMASOFT 9 and FLOW-3D. 10 Another example of fluid flow analysis in modelling of manufacturing processes has been given by Zhang and Wu, 11 in which they investigated the effect of fluid flow in the weld pool on the numerical simulation accuracy of the thermal field in hybrid welding.…”

Section: Introductionmentioning

confidence: 99%

Multiphysics modelling of manufacturing processes: A review

Jabbari

Baran

Mohanty³

et al. 2018

Advances in Mechanical Engineering

View full text Add to dashboard Cite

Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. On the other hand, processes which inherently may seem multiphysical by nature might sometimes be modelled by considerably simpler models if the problem at hand can be somehow adequately simplified. In the present article, examples of this will be presented. The cases are chosen with the aim of showing the diversity in the field of modelling of manufacturing processes as regards process, materials, generic disciplines as well as length scales: (1) modelling of tape casting for thin ceramic layers, (2) modelling the flow of polymers in extrusion, (3) modelling the deformation process of flexible stamps for nanoimprint lithography, (4) modelling manufacturing of composite parts and (5) modelling the selective laser melting process. For all five examples, the emphasis is on modelling results as well as describing the models in brief mathematical details. Alongside with relevant references to the original work, proper comparison with experiments is given in some examples for model validation.

show abstract

The modelling of oxide film entrainment in casting systems using computational modelling

Cited by 21 publications

References 16 publications

Bifilm Defect Formation in Hydraulic Jump of Liquid Aluminum

Bifilm Defect Formation in Hydraulic Jump of Liquid Aluminum

A Computational Framework Towards Energy Efficient Casting Processes

Multiphysics modelling of manufacturing processes: A review

Contact Info

Product

Resources

About