Simulation of Flow Field and Temperature Tield in the Process of Filling and Solidification for K424 Alloy Thin-Walled Casting

2011 ◽  
Vol 66-68 ◽  
pp. 1568-1573
Author(s):  
Xin Wang ◽  
Zhi Jun Zhang
Keyword(s):  
Flow Field ◽  
Three Dimensional ◽  
Solidification Process ◽  
Temperature Changes ◽  
Theoretical Support ◽  
Alloy Castings ◽  
Dimensional Simulation ◽  
Filling Simulation ◽  
Cast Analysis ◽  
Filling And Solidification

In order to improve the utilization of K424 alloy, Z-Cast analysis software is used to get three-dimensional flow field and temperature coupling simulation in the process of K424 alloy castings filling, by considering the effection of pouring temperature, casting speed, shell thermal conductivity and temperature on the morphology of filling.A three-dimensional simulation of temperature changes in solidification process of molten metal was performed based on the filling simulation. The simulation results on flow field and temperature field shows the order of filling and solidification in different parts of the casting ,and determines the position where cold shut and misrun appears, which provides theoretical support to the improvement of technology plan.

Analysis of Shrinkage Characteristics of Aluminium Silicon Alloy

2016 ◽  
Vol 16 (3) ◽  
pp. 163-171 ◽  
Author(s):  
Syed Ferhathullah Hussainy ◽  
Mohd. Viquar Mohiuddin ◽  
P. Laxminarayana ◽  
S. Sundarrajan ◽  
A. Krishnaiah
Keyword(s):  
Solidification Process ◽  
Literature Survey ◽  
Extensive Literature ◽  
Industrial Environment ◽  
Silicon Alloy ◽  
Casting Yield ◽  
Cavity Filling ◽  
Alloy Castings ◽  
Filling And Solidification ◽  
Critical Aspects

AbstractAnalysis of shrinkage characteristics of Aluminium-Silicon alloy was studied theoretically and experimentally. The Aluminium alloys considered in the study are A413 (LM6), A360 (LM9) and A380 (LM24). Extensive literature survey has suggested that cavity filling and solidification process are two most critical aspects to produce high quality casting components. A statistical model of parameters and response to understand the influence of parameters on shrinkage and casting yield studies has been presented. Experiments were conducted in foundry in industrial environment to produce commercially treated aluminium alloy castings in sand mould. Alloy was found to be most significant factor influencing shrinkage. The yield of casting was improved using insulating and exothermic sleeves. Solidification time of exothermic riser was 10 % more than insulated riser. Thus, in order to produce radiographic quality casting a theoretical and experimental method is presented so that number of trials in foundry is reduced which leads to increased reliability and productivity. Study also shows that by using sleeves considerable metal is saved, energy saving during melting, improved quality, reduced cost and increased capacity of plant can be achieved.

Analysis on the Inhomogeneity of Air Intake and Retrofit Optimization of the Air Intake Pipe in the Engine T12V190

2014 ◽  
Vol 635-637 ◽  
pp. 7-12
Author(s):  
Xiao Jie Li ◽  
Zhong Yu Zhao ◽  
Yu Tian Pan
Keyword(s):  
Flow Field ◽  
Three Dimensional ◽  
Three Dimension ◽  
Intake Pipe ◽  
Performance Reduction ◽  
Cavity Structure ◽  
Air Intake ◽  
Dimensional Simulation ◽  
And Performance ◽  
Retrofit Design

Taking the air intake pipe in the engine as the target of the research, the software STAR-CDE is adopted to build a three-dimensional simulation model for the air intake pipe in the engine T12V190 with the aim to solve the problems of air input deficiency, Combustion deterioration and performance reduction of one cylinder caused by the non-uniformity. Moreover, the non-uniformity of the flux of air intake of the air intake pipe is mainly studied and analyzed through a calculation on the CFD of the inner flow field of the three dimension of the air intake pipe in the engine T12V190. In addition, a retrofit design with multiple schemes is made based on the cavity structure of the original mold for the air intake pipe. Finally, through a comparison among the three selected designs, a more feasible retrofit designing scheme and a designing thought on the air intake pipe in the engine with directional significance are got.

Numerical Simulation of Grain Selection Behavior of Single Crystal Ni3Al Based Superalloy Casting

2010 ◽  
Vol 654-656 ◽  
pp. 1482-1485
Author(s):  
Dong Pan ◽  
Qing Yan Xu ◽  
Bai Cheng Liu
Keyword(s):  
Single Crystal ◽  
Selection Process ◽  
Three Dimensional ◽  
Solidification Process ◽  
Middle Part ◽  
Selection Behavior ◽  
Final Microstructure ◽  
Dimensional Simulation ◽  
Stray Grains ◽  
Stray Grain

Ni3Al based superalloy has recently been used for the single crystal gas turbine blade. The grain selection behavior in grain selector directly determines the casting’s final microstructure and properties. A mathematical model based on the modified CA-FD method was developed for the three-dimensional simulation of directional solidification process of Ni3Al based single crystal superalloy castings. The microstructure evolution was simulated with the modified Cellular Automaton method. The grain selection process in the grain selector and final microstructure of casting were simulated. The results indicate that the stray grain is easy to nucleate at the middle part of the pigtail because of the discontinuous mushy zones formation. This agrees with previous published experimental results. Based on simulated results, a newly designed grain selector with optimized geometry was proposed to avoid stray grains.

Numerical Simulation of Multiple Seeds Interaction During Three-Dimensional Dendritic Solidification With Fluid Flow

2009 ◽  
Author(s):  
Ikroh Yoon ◽  
Seungwon Shin
Keyword(s):  
Numerical Simulation ◽  
Fluid Flow ◽  
Numerical Technique ◽  
Three Dimensional ◽  
Solidification Process ◽  
Small Scale ◽  
Reconstruction Method ◽  
External Fluid ◽  
Fluid Convection ◽  
Dimensional Simulation

Most material of engineering interest undergoes solidification process from liquid to solid state which governs the microstructure of materials. Identifying the growth characteristic of the microstructure during the solidification process is essential to determine the physical properties of final product. Numerical simulation can provide valuable information during solidification process since heat and mass transfer associated with micro-structural growth of dendrite is in greatly small scale which is almost impossible to obtain by experiments. In real situations, dendrite tends to grow from multiple seeds as well as with external fluid flow. Growth characteristics of the dendrites will be greatly influenced by both external fluid convection and interaction between dendrites. In this paper, three-dimensional numerical simulation of multiple dendritic growth during solidification process with melt fluid convection is presented. The high-order Level Contour Reconstruction Method (LCRM), a hybrid form of Front-Tracking and Level-Set, is used to track the moving liquid-solid interface explicitly and sharp interface technique has been used to implement correct phase changing boundary conditions on the moving interface. To get the indicator function and the interface curvature more efficiently and accurately for three-dimensional simulation, we have generated the distance function directly from the interface. The method is validated by comparing with other numerical technique and showed good agreements. Three-dimensional results showed clear difference compared to two-dimensional simulation on growth behavior, especially with multiple seeds.

Numerical Simulation of Unidirectional Solidification Process of Turbine Blade Castings

2007 ◽  
Vol 26-28 ◽  
pp. 947-952 ◽  
Author(s):  
Jing Yu ◽  
Qing Yan Xu ◽  
Bai Cheng Liu ◽  
Jia Rong Li ◽  
Hai Long Yuan
Keyword(s):  
Temperature Difference ◽  
Outer Space ◽  
Three Dimensional ◽  
Solidification Process ◽  
Unidirectional Solidification ◽  
Withdrawal Rate ◽  
Heat Radiation ◽  
Horizontal Section ◽  
Dimensional Simulation ◽  
Stray Grains

A mathematical model for three-dimensional simulation of unidirectional solidification process and microstructure evolution of Ni-based superalloy investment castings was developed based on CA-FD method. The modified ray tracing method was used to solve the complicated heat radiation transfer among the multiple blades and outer space during withdrawal process. Various withdrawal rates were used. During one process high withdrawal rate was used first before the platform approached the baffle. Then the low withdrawal rate was used to reduce the temperature difference of the platform in horizontal section and avoid the defects formed in the corner of the platform. The experimental cooling curves of different positions in the blades and microstructure were compared with the simulation results. Both the results showed that the various withdrawal rates process was effective to reduce the temperature difference of the platform and avoid the formation of stray grains. This process could be helpful to increase the productivity.

Three-Dimensional Simulation of Planar Solid Oxide Fuel Cell Stack

2008 ◽  
Vol 128 (2) ◽  
pp. 459-466 ◽  
Author(s):  
Yoshitaka Inui ◽  
Tadashi Tanaka ◽  
Tomoyoshi Kanno
Keyword(s):  
Fuel Cell ◽  
Solid Oxide Fuel Cell ◽  
Three Dimensional ◽  
Solid Oxide ◽  
Oxide Fuel ◽  
Fuel Cell Stack ◽  
Dimensional Simulation
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