The solidification of metals continues to be a
phenomenon of great interest to physicists, metallurgists, casting
engineers, and software developers. It is a non-linear transient
phenomenon, posing a challenge in terms of modeling and
analysis. During the solidification of a casting in a mould, the
heat-transfer between the casting and the mould plays a vital
role. This paper attempts to study heat flow within the casting, as
well as from the casting to the mould, and finally obtains the
temperature history of some points inside the casting. The most
important instant of time is when the hottest region inside the
casting is solidifying. ProCAST software has been used to obtain
the temperature distribution in the casting process by performing
Transient Thermal Analysis. In this research work, solidification
of lead-2wt%antimony alloy has been carried out in the different
sizes of metallic mold to predict the formation of shrinkage
during solidification. Theoretical results have been validated
experimentally for a particular case of lead-2wt%antimony alloy
solidification. Results obtained by simulation software are
compared with the experimental reading of temperature and
found to be in good agreement. Voids appeared at the top and
isolated area of castings for the defect-free direct method used in
this study.