As a standard test-bar permanent mould, the “Stahl” Mould has been widely used in foundries to assess the properties of aluminium cast alloys. However, lower mechanical properties are often obtained with this mould due to filling turbulence and shrinkage-induced microporosity in the gauge section. In order to improve the mechanical properties, a new design of test-bar permanent mould was evaluated and studied in this work by computer aided simulation. Numerical simulations have been performed to study the filling and solidification behaviour of an A356 alloy, in order to predict the turbulence of the melt and the microshrinkage formation. Different process parameters, such as the temperature of the bath and the die, the use of a foam filter were systematically varied and analysed in the design of experimental matrix.
Optimization of a Permanent Test-Bar Mould to Evaluate the Quality of Molten Aluminium Alloys
CALIARI, DANIELE;TIMELLI, GIULIO
2014
Abstract
As a standard test-bar permanent mould, the “Stahl” Mould has been widely used in foundries to assess the properties of aluminium cast alloys. However, lower mechanical properties are often obtained with this mould due to filling turbulence and shrinkage-induced microporosity in the gauge section. In order to improve the mechanical properties, a new design of test-bar permanent mould was evaluated and studied in this work by computer aided simulation. Numerical simulations have been performed to study the filling and solidification behaviour of an A356 alloy, in order to predict the turbulence of the melt and the microshrinkage formation. Different process parameters, such as the temperature of the bath and the die, the use of a foam filter were systematically varied and analysed in the design of experimental matrix.
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