Electromagnetic metal casting (EMC) is a casting technique that uses electromagnetic energy to heat metal powders. It is a faster, cleaner, and less time-consuming operation. Solid metals create issues in electromagnetics since they reflect the electromagnetic radiation rather than consume it—electromagnetic energy processing results in sounded pieces with higher-ranking material properties and a more excellent microstructure solution. For the physical production of the electromagnetic casting process, knowledge of electromagnetic material interaction is critical. Even where the heated material is an excellent electromagnetic absorber, the total heating quality is sometimes insufficient. Numerical modelling works on finding the proper coupled effects between properties to bring out the most effective operation. The main parameters influencing the quality of output of the EMC process are: power dissipated per unit volume into the material, penetration depth of electromagnetics, complex magnetic permeability and complex dielectric permittivity. The contact mechanism and interference pattern also, in turn, determines the quality of the process. Only a few parameters, such as the environment’s temperature, the interference pattern, and the rate of metal solidification, can be controlled by AI models. Neural networks are used to achieve exact outcomes by stimulating the neurons in the human brain. Additive manufacturing (AM) is used to design mold and cores for metal casting. The models outperformed the traditional DFA optimization approach, which is susceptible to local minima. The system works only offline, so real-time analysis and corrections are not yet possible.
Korea Abstract
전자기 금속 주조 (EMC)는 전자기 에너지를 사용하여 금속 분말을 가열하는 주조 기술입니다. 더 빠르고 깨끗하며 시간이 덜 소요되는 작업입니다.
고체 금속은 전자기 복사를 소비하는 대신 반사하기 때문에 전자기학에서 문제를 일으킵니다. 전자기 에너지 처리는 더 높은 등급의 재료 특성과 더 우수한 미세 구조 솔루션을 가진 사운드 조각을 만듭니다.
전자기 주조 공정의 물리적 생산을 위해서는 전자기 물질 상호 작용에 대한 지식이 중요합니다. 가열된 물질이 우수한 전자기 흡수재인 경우에도 전체 가열 품질이 때때로 불충분합니다. 수치 모델링은 가장 효과적인 작업을 이끌어 내기 위해 속성 간의 적절한 결합 효과를 찾는데 사용됩니다.
EMC 공정의 출력 품질에 영향을 미치는 주요 매개 변수는 단위 부피당 재료로 분산되는 전력, 전자기의 침투 깊이, 복합 자기 투과성 및 복합 유전율입니다. 접촉 메커니즘과 간섭 패턴 또한 공정의 품질을 결정합니다. 환경 온도, 간섭 패턴 및 금속 응고 속도와 같은 몇 가지 매개 변수 만 AI 모델로 제어 할 수 있습니다.
신경망은 인간 뇌의 뉴런을 자극하여 정확한 결과를 얻기 위해 사용됩니다. 적층 제조 (AM)는 금속 주조용 몰드 및 코어를 설계하는 데 사용됩니다. 모델은 로컬 최소값에 영향을 받기 쉬운 기존 DFA 최적화 접근 방식을 능가했습니다. 이 시스템은 오프라인에서만 작동하므로 실시간 분석 및 수정은 아직 불가능합니다.
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아래는 FSI의 금속 주조 참고 문헌에 수록된 기술 논문 모음입니다. 이 모든 논문에는 FLOW-3D CAST 해석 결과가 수록되어 있습니다. FLOW-3D CAST를 사용하여 금속 주조 산업의 응용 프로그램을 성공적으로 시뮬레이션하는 방법에 대해 자세히 알아보십시오.
Below is a collection of technical papers in our Metal Casting Bibliography. All of these papers feature FLOW-3D CAST results. Learn more about how FLOW-3D CAST can be used to successfully simulate applications for the Metal Casting Industry.
20-20 Wu Yue, Li Zhuo and Lu Rong, Simulation and visual tester verification of solid propellant slurry vacuum plate casting, Propellants, Explosives, Pyrotechnics, 2020. doi.org/10.1002/prep.201900411
17-20 C.A. Jones, M.R. Jolly, A.E.W. Jarfors and M. Irwin, An experimental characterization of thermophysical properties of a porous ceramic shell used in the investment casting process, Supplimental Proceedings, pp. 1095-1105, TMS 2020 149th Annual Meeting and Exhibition, San Diego, CA, February 23-27, 2020. doi.org/10.1007/978-3-030-36296-6_102
12-20 Franz Josef Feikus, Paul Bernsteiner, Ricardo Fernández Gutiérrez and Michal Luszczak , Further development of electric motor housings, MTZ Worldwide, 81, pp. 38-43, 2020. doi.org/10.1007/s38313-019-0176-z
09-20 Mingfan Qi, Yonglin Kang, Yuzhao Xu, Zhumabieke Wulabieke and Jingyuan Li, A novel rheological high pressure die-casting process for preparing large thin-walled Al–Si–Fe–Mg–Sr alloy with high heat conductivity, high plasticity and medium strength, Materials Science and Engineering: A, 776, art. no. 139040, 2020. doi.org/10.1016/j.msea.2020.139040
07-20 Stefan Heugenhauser, Erhard Kaschnitz and Peter Schumacher, Development of an aluminum compound casting process – Experiments and numerical simulations, Journal of Materials Processing Technology, 279, art. no. 116578, 2020. doi.org/10.1016/j.jmatprotec.2019.116578
05-20 Michail Papanikolaou, Emanuele Pagone, Mark Jolly and Konstantinos Salonitis, Numerical simulation and evaluation of Campbell running and gating systems, Metals, 10.1, art. no. 68, 2020. doi.org/10.3390/met10010068
102-19 Ferencz Peti and Gabriela Strnad, The effect of squeeze pin dimension and operational parameters on material homogeneity of aluminium high pressure die cast parts, Acta Marisiensis. Seria Technologica, 16.2, 2019. doi.org/0.2478/amset-2019-0010
94-19 E. Riedel, I. Horn, N. Stein, H. Stein, R. Bahr, and S. Scharf, Ultrasonic treatment: a clean technology that supports sustainability incasting processes, Procedia, 26th CIRP Life Cycle Engineering (LCE) Conference, Indianapolis, Indiana, USA, May 7-9, 2019.
93-19 Adrian V. Catalina, Liping Xue, Charles A. Monroe, Robin D. Foley, and John A. Griffin, Modeling and Simulation of Microstructure and Mechanical Properties of AlSi- and AlCu-based Alloys, Transactions, 123rd Metalcasting Congress, Atlanta, GA, USA, April 27-30, 2019.
84-19 Arun Prabhakar, Michail Papanikolaou, Konstantinos Salonitis, and Mark Jolly, Sand casting of sheet lead: numerical simulation of metal flow and solidification, The International Journal of Advanced Manufacturing Technology, pp. 1-13, 2019. doi.org/10.1007/s00170-019-04522-3
71-19 Sebastian Findeisen, Robin Van Der Auwera, Michael Heuser, and Franz-Josef Wöstmann, Gießtechnische Fertigung von E-Motorengehäusen mit interner Kühling (Casting production of electric motor housings with internal cooling), Geisserei, 106, pp. 72-78, 2019 (in German).
58-19 Von Malte Leonhard, Matthias Todte, and Jörg Schäffer, Realistic simulation of the combustion of exothermic feeders, Casting, No. 2, pp. 28-32, 2019. In English and German.
47-19 Bing Zhou, Shuai Lu, Kaile Xu, Chun Xu, and Zhanyong Wang, Microstructure and simulation of semisolid aluminum alloy castings in the process of stirring integrated transfer-heat (SIT) with water cooling, International Journal of Metalcasting, Online edition, pp. 1-13, 2019. doi.org/10.1007/s40962-019-00357-6
31-19 Zihao Yuan, Zhipeng Guo, and S.M. Xiong, Skin layer of A380 aluminium alloy die castings and its blistering during solution treatment, Journal of Materials Science & Technology, Vol. 35, No. 9, pp. 1906-1916, 2019. doi.org/10.1016/j.jmst.2019.05.011
25-19 Stefano Mascetti, Raul Pirovano, and Giulio Timelli, Interazione metallo liquido/stampo: Il fenomeno della metallizzazione, La Metallurgia Italiana, No. 4, pp. 44-50, 2019. In Italian.
20-19 Fu-Yuan Hsu, Campbellology for runner system design, Shape Casting: The Minerals, Metals & Materials Series, pp. 187-199, 2019. doi.org/10.1007/978-3-030-06034-3_19
19-19 Chengcheng Lyu, Michail Papanikolaou, and Mark Jolly, Numerical process modelling and simulation of Campbell running systems designs, Shape Casting: The Minerals, Metals & Materials Series, pp. 53-64, 2019. doi.org/10.1007/978-3-030-06034-3_5
18-19 Adrian V. Catalina, Liping Xue, and Charles Monroe, A solidification model with application to AlSi-based alloys, Shape Casting: The Minerals, Metals & Materials Series, pp. 201-213, 2019. doi.org/10.1007/978-3-030-06034-3_20
17-19 Fu-Yuan Hsu and Yu-Hung Chen, The validation of feeder modeling for ductile iron castings, Shape Casting: The Minerals, Metals & Materials Series, pp. 227-238, 2019. doi.org/10.1007/978-3-030-06034-3_22
02-19 Jingying Sun, Qichi Le, Li Fu, Jing Bai, Johannes Tretter, Klaus Herbold and Hongwei Huo, Gas entrainment behavior of aluminum alloy engine crankcases during the low-pressure-die-casting-process, Journal of Materials Processing Technology, Vol. 266, pp. 274-282, 2019. doi.org/10.1016/j.jmatprotec.2018.11.016
92-18Fast, Flexible… More Versatile, Foundry Management Technology, March, 2018.
82-18 Xu Zhao, Ping Wang, Tao Li, Bo-yu Zhang, Peng Wang, Guan-zhou Wang and Shi-qi Lu, Gating system optimization of high pressure die casting thin-wall AlSi10MnMg longitudinal loadbearing beam based on numerical simulation, China Foundry, Vol. 15, no. 6, pp. 436-442, 2018. doi: 10.1007/s41230-018-8052-z
80-18 Michail Papanikolaou, Emanuele Pagone, Konstantinos Salonitis, Mark Jolly and Charalampos Makatsoris, A computational framework towards energy efficient casting processes, Sustainable Design and Manufacturing 2018: Proceedings of the 5th International Conference on Sustainable Design and Manufacturing (KES-SDM-18), Gold Coast, Australia, June 24-26 2018, SIST 130, pp. 263-276, 2019. doi.org/10.1007/978-3-030-04290-5_27
51-18 Xue-feng Zhu, Bao-yi Yu, Li Zheng, Bo-ning Yu, Qiang Li, Shu-ning Lü and Hao Zhang, Influence of pouring methods on filling process, microstructure and mechanical properties of AZ91 Mg alloy pipe by horizontal centrifugal casting, China Foundry, vol. 15, no. 3, pp.196-202, 2018. doi.org/10.1007/s41230-018-7256-6
47-18 Santosh Reddy Sama, Jiayi Wang and Guha Manogharan, Non-conventional mold design for metal casting using 3D sand-printing, Journal of Manufacturing Processes, vol. 34-B, pp. 765-775, 2018. doi.org/10.1016/j.jmapro.2018.03.049
42-18 M. Koru and O. Serçe, The Effects of Thermal and Dynamical Parameters and Vacuum Application on Porosity in High-Pressure Die Casting of A383 Al-Alloy, International Journal of Metalcasting, pp. 1-17, 2018. doi.org/10.1007/s40962-018-0214-7
41-18 Abhilash Viswanath, S. Savithri, U.T.S. Pillai, Similitude analysis on flow characteristics of water, A356 and AM50 alloys during LPC process, Journal of Materials Processing Technology, vol. 257, pp. 270-277, 2018. doi.org/10.1016/j.jmatprotec.2018.02.031
29-18 Seyboldt, Christoph and Liewald, Mathias, Investigation on thixojoining to produce hybrid components with intermetallic phase, AIP Conference Proceedings, vol. 1960, no. 1, 2018. doi.org/10.1063/1.5034992
28-18 Laura Schomer, Mathias Liewald and Kim Rouven Riedmüller, Simulation of the infiltration process of a ceramic open-pore body with a metal alloy in semi-solid state to design the manufacturing of interpenetrating phase composites, AIP Conference Proceedings, vol. 1960, no. 1, 2018. doi.org/10.1063/1.5034991
88-16 M.C. Carter, T. Kauffung, L. Weyenberg and C. Peters, Low Pressure Die Casting Simulation Discovery through Short Shot, Cast Expo & Metal Casting Congress, April 16-19, 2016, Minneapolis, MN, Copyright 2016 American Foundry Society.
20-16 Fu-Yuan Hsu, Bifilm Defect Formation in Hydraulic Jump of Liquid Aluminum, Metallurgical and Materials Transactions B, 2016, Band: 47, Heft 3, 1634-1648.
15-16 Mingfan Qia, Yonglin Kanga, Bing Zhoua, Wanneng Liaoa, Guoming Zhua, Yangde Lib,and Weirong Li, A forced convection stirring process for Rheo-HPDC aluminum and magnesium alloys, Journal of Materials Processing Technology 234 (2016) 353–367
112-15 José Miguel Gonçalves Ledo Belo da Costa, Optimization of filling systems for low pressure by FLOW-3D, Dissertação de mestrado integrado em Engenharia Mecânica, 2015.
88-15 Peng Zhang, Zhenming Li, Baoliang Liu, Wenjiang Ding and Liming Peng, Improved tensile properties of a new aluminum alloy for high pressure die casting, Materials Science & Engineering A651(2016)376–390, Available online, November 2015.
82-15 J. Müller, L. Xue, M.C. Carter, C. Thoma, M. Fehlbier and M. Todte, A Die Spray Cooling Model for Thermal Die Cycling Simulations, 2015 Die Casting Congress & Exposition, Indianapolis, IN, October 2015
81-15 M. T. Murray, L.F. Hansen, L. Chilcott, E. Li and A.M. Murray, Case Studies in the Use of Simulation- Improved Yield and Reduced Time to Market, 2015 Die Casting Congress & Exposition, Indianapolis, IN, October 2015
80-15 R. Bhola, S. Chandra and D. Souders, Predicting Castability of Thin-Walled Parts for the HPDC Process Using Simulations, 2015 Die Casting Congress & Exposition, Indianapolis, IN, October 2015
76-15 Prosenjit Das, Sudip K. Samanta, Shashank Tiwari and Pradip Dutta, Die Filling Behaviour of Semi Solid A356 Al Alloy Slurry During Rheo Pressure Die Casting, Transactions of the Indian Institute of Metals, pp 1-6, October 2015
74-15 Murat KORU and Orhan SERÇE, Yüksek Basınçlı Döküm Prosesinde Enjeksiyon Parametrelerine Bağlı Olarak Döküm Simülasyon, Cumhuriyet University Faculty of Science, Science Journal (CSJ), Vol. 36, No: 5 (2015) ISSN: 1300-1949, May 2015
69-15 A. Viswanath, S. Sivaraman, U. T. S. Pillai, Computer Simulation of Low Pressure Casting Process Using FLOW-3D, Materials Science Forum, Vols. 830-831, pp. 45-48, September 2015
68-15 J. Aneesh Kumar, K. Krishnakumar and S. Savithri, Computer Simulation of Centrifugal Casting Process Using FLOW-3D, Materials Science Forum, Vols. 830-831, pp. 53-56, September 2015
59-15 F. Hosseini Yekta and S. A. Sadough Vanini, Simulation of the flow of semi-solid steel alloy using an enhanced model, Metals and Materials International, August 2015.
138-14 Christopher Thoma, Wolfram Volk, Ruben Heid, Klaus Dilger, Gregor Banner and Harald Eibisch, Simulation-based prediction of the fracture elongation as a failure criterion for thin-walled high-pressure die casting components, International Journal of Metalcasting, Vol. 8, No. 4, pp. 47-54, 2014. doi.org/10.1007/BF03355594
107-14 Mehran Seyed Ahmadi, Dissolution of Si in Molten Al with Gas Injection, ProQuest Dissertations And Theses; Thesis (Ph.D.), University of Toronto (Canada), 2014; Publication Number: AAT 3637106; ISBN: 9781321195231; Source: Dissertation Abstracts International, Volume: 76-02(E), Section: B.; 191 p.
92-14 Warren Bishenden and Changhua Huang, Venting design and process optimization of die casting process for structural components; Part II: Venting design and process optimization, Die Casting Engineer, November 2014
90-14 Ken’ichi Kanazawa, Ken’ichi Yano, Jun’ichi Ogura, and Yasunori Nemoto, Optimum Runner Design for Die-Casting using CFD Simulations and Verification with Water-Model Experiments, Proceedings of the ASME 2014 International Mechanical Engineering Congress and Exposition, IMECE2014, November 14-20, 2014, Montreal, Quebec, Canada, IMECE2014-37419
89-14 P. Kapranos, C. Carney, A. Pola, and M. Jolly, Advanced Casting Methodologies: Investment Casting, Centrifugal Casting, Squeeze Casting, Metal Spinning, and Batch Casting, In Comprehensive Materials Processing; McGeough, J., Ed.; 2014, Elsevier Ltd., 2014; Vol. 5, pp 39–67.
68-14 L. Xue, M.C. Carter, A.V. Catalina, Z. Lin, C. Li, and C. Qiu, Numerical Simulation of Core Gas Defects in Steel Castings, Copyright 2014 American Foundry Society, 118th Metalcasting Congress, April 8 – 11, 2014, Schaumburg, IL
51-14 Jesus M. Blanco, Primitivo Carranza, Rafael Pintos, Pedro Arriaga, and Lakhdar Remaki, Identification of Defects Originated during the Filling of Cast Pieces through Particles Modelling, 11th World Congress on Computational Mechanics (WCCM XI), 5th European Conference on Computational Mechanics (ECCM V), 6th European Conference on Computational Fluid Dynamics (ECFD VI), E. Oñate, J. Oliver and A. Huerta (Eds)
47-14 B. Vijaya Ramnatha, C.Elanchezhiana, Vishal Chandrasekhar, A. Arun Kumarb, S. Mohamed Asif, G. Riyaz Mohamed, D. Vinodh Raj , C .Suresh Kumar, Analysis and Optimization of Gating System for Commutator End Bracket, Procedia Materials Science 6 ( 2014 ) 1312 – 1328, 3rd International Conference on Materials Processing and Characterisation (ICMPC 2014)
20-14 Johannes Hartmann, Tobias Fiegl, Carolin Körner, Aluminum integral foams with tailored density profile by adapted blowing agents, Applied Physics A, doi.org/10.1007/s00339-014-8377-4, March 2014.
08-14 FY Hsu, SW Wang, and HJ Lin, The External and Internal Shrinkages in Aluminum Gravity Castings, Shape Casting: 5th International Symposium 2014. Available online at Google Books
103-13 B. Fuchs, H. Eibisch and C. Körner, Core Viability Simulation for Salt Core Technology in High-Pressure Die Casting, International Journal of Metalcasting, July 2013, Volume 7, Issue 3, pp 39–45
84-13 Körner, C., Schwankl, M., Himmler, D., Aluminum-Aluminum compound castings by electroless deposited zinc layers, Journal of Materials Processing Technology (2014), doi.org/10.1016/j.jmatprotec.2013.12.01483-13.
77-13 Antonio Armillotta & Raffaello Baraggi & Simone Fasoli, SLM tooling for die casting with conformal cooling channels, The International Journal of Advanced Manufacturing Technology, doi.org/10.1007/s00170-013-5523-7, December 2013.
64-13 Johannes Hartmann, Christina Blümel, Stefan Ernst, Tobias Fiegl, Karl-Ernst Wirth, Carolin Körner, Aluminum integral foam castings with microcellular cores by nano-functionalization, J Mater Sci, doi.org/10.1007/s10853-013-7668-z, September 2013.
42-13 Yang Yue, William D. Griffiths, and Nick R. Green, Modelling of the Effects of Entrainment Defects on Mechanical Properties in a Cast Al-Si-Mg Alloy, Materials Science Forum, 765, 225, 2013.
39-13 J. Crapps, D.S. DeCroix, J.D Galloway, D.A. Korzekwa, R. Aikin, R. Fielding, R. Kennedy, C. Unal, Separate effects identification via casting process modeling for experimental measurement of U-Pu-Zr alloys, Journal of Nuclear Materials, 15 July 2013.
09-13 M.C. Carter and L. Xue, Simulating the Parameters that Affect Core Gas Defects in Metal Castings, Copyright 2012 American Foundry Society, Presented at the 2013 CastExpo, St. Louis, Missouri, April 2013
08-13 C. Reilly, N.R. Green, M.R. Jolly, J.-C. Gebelin, The Modelling Of Oxide Film Entrainment In Casting Systems Using Computational Modelling, Applied Mathematical Modelling, http://dx.doi.org/10.1016/j.apm.2013.03.061, April 2013.
03-13 Alexandre Reikher and Krishna M. Pillai, A fast simulation of transient metal flow and solidification in a narrow channel. Part II. Model validation and parametric study, Int. J. Heat Mass Transfer (2013), http://dx.doi.org/10.1016/j.ijheatmasstransfer.2012.12.061.
02-13 Alexandre Reikher and Krishna M. Pillai, A fast simulation of transient metal flow and solidification in a narrow channel. Part I: Model development using lubrication approximation, Int. J. Heat Mass Transfer (2013), http://dx.doi.org/10.1016/j.ijheatmasstransfer.2012.12.060.
116-12 Jufu Jianga, Ying Wang, Gang Chena, Jun Liua, Yuanfa Li and Shoujing Luo, “Comparison of mechanical properties and microstructure of AZ91D alloy motorcycle wheels formed by die casting and double control forming, Materials & Design, Volume 40, September 2012, Pages 541-549.
103-12 WU Shu-sen, ZHONG Gu, AN Ping, WAN Li, H. NAKAE, Microstructural characteristics of Al−20Si−2Cu−0.4Mg−1Ni alloy formed by rheo-squeeze casting after ultrasonic vibration treatment, Transactions of Nonferrous Metals Society of China, 22 (2012) 2863-2870, November 2012. Full paper available online.
97-12 Hong Zhou and Li Heng Luo, Filling Pattern of Step Gating System in Lost Foam Casting Process and its Application, Advanced Materials Research, Volumes 602-604, Progress in Materials and Processes, 1916-1921, December 2012.
93-12 Liangchi Zhang, Chunliang Zhang, Jeng-Haur Horng and Zichen Chen, Functions of Step Gating System in the Lost Foam Casting Process, Advanced Materials Research, 591-593, 940, DOI: 10.4028/www.scientific.net/AMR.591-593.940, November 2012.
91-12 Hong Yan, Jian Bin Zhu, Ping Shan, Numerical Simulation on Rheo-Diecasting of Magnesium Matrix Composites, 10.4028/www.scientific.net/SSP.192-193.287, Solid State Phenomena, 192-193, 287.
89-12 Alexandre Reikher and Krishna M. Pillai, A Fast Numerical Simulation for Modeling Simultaneous Metal Flow and Solidification in Thin Cavities Using the Lubrication Approximation, Numerical Heat Transfer, Part A: Applications: An International Journal of Computation and Methodology, 63:2, 75-100, November 2012.
82-12 Jufu Jiang, Gang Chen, Ying Wang, Zhiming Du, Weiwei Shan, and Yuanfa Li, Microstructure and mechanical properties of thin-wall and high-rib parts of AM60B Mg alloy formed by double control forming and die casting under the optimal conditions, Journal of Alloys and Compounds, http://dx.doi.org/10.1016/j.jallcom.2012.10.086, October 2012.
65-12 X.H. Yang, T.J. Lu, T. Kim, Influence of non-conducting pore inclusions on phase change behavior of porous media with constant heat flux boundary, International Journal of Thermal Sciences, Available online 10 October 2012. Available online at SciVerse.
55-12 Hejun Li, Pengyun Wang, Lehua Qi, Hansong Zuo, Songyi Zhong, Xianghui Hou, 3D numerical simulation of successive deposition of uniform molten Al droplets on a moving substrate and experimental validation, Computational Materials Science, Volume 65, December 2012, Pages 291–301.
52-12 Hongbing Ji, Yixin Chen and Shengzhou Chen, Numerical Simulation of Inner-Outer Couple Cooling Slab Continuous Casting in the Filling Process, Advanced Materials Research (Volumes 557-559), Advanced Materials and Processes II, pp. 2257-2260, July 2012.
47-12 Petri Väyrynen, Lauri Holappa, and Seppo Louhenkilpi, Simulation of Melting of Alloying Materials in Steel Ladle, SCANMET IV – 4th International Conference on Process Development in Iron and Steelmaking, Lulea, Sweden, June 10-13, 2012.
45-12 D.R. Gunasegaram, M. Givord, R.G. O’Donnell and B.R. Finnin, Improvements engineered in UTS and elongation of aluminum alloy high pressure die castings through the alteration of runner geometry and plunger velocity, Materials Science & Engineering.
41-12 Deniece R. Korzekwa, Cameron M. Knapp, David A. Korzekwa, and John W. Gibbs, Co-Design – Fabrication of Unalloyed Plutonium, LA-UR-12-23441, MDI Summer Research Group Workshop Advanced Manufacturing, 2012-07-25/2012-07-26 (Los Alamos, New Mexico, United States)
29-12 Dario Tiberto and Ulrich E. Klotz, Computer simulation applied to jewellery casting: challenges, results and future possibilities, IOP Conf. Ser.: Mater. Sci. Eng.33 012008. Full paper available at IOP.
28-12 Y Yue and N R Green, Modelling of different entrainment mechanisms and their influences on the mechanical reliability of Al-Si castings, 2012 IOP Conf. Ser.: Mater. Sci. Eng. 33,012072.Full paper available at IOP.
27-12 E Kaschnitz, Numerical simulation of centrifugal casting of pipes, 2012 IOP Conf. Ser.: Mater. Sci. Eng. 33 012031, Issue 1. Full paper available at IOP.
15-12 C. Reilly, N.R Green, M.R. Jolly, The Present State Of Modeling Entrainment Defects In The Shape Casting Process, Applied Mathematical Modelling, Available online 27 April 2012, ISSN 0307-904X, 10.1016/j.apm.2012.04.032.
12-12 Andrei Starobin, Tony Hirt, Hubert Lang, and Matthias Todte, Core drying simulation and validation, International Foundry Research, GIESSEREIFORSCHUNG 64 (2012) No. 1, ISSN 0046-5933, pp 2-5
04-12 J. Spangenberg, N. Roussel, J.H. Hattel, H. Stang, J. Skocek, M.R. Geiker, Flow induced particle migration in fresh concrete: Theoretical frame, numerical simulations and experimental results on model fluids, Cement and Concrete Research, http://dx.doi.org/10.1016/j.cemconres.2012.01.007, February 2012.
01-12 Lee, B., Baek, U., and Han, J., Optimization of Gating System Design for Die Casting of Thin Magnesium Alloy-Based Multi-Cavity LCD Housings, Journal of Materials Engineering and Performance, Springer New York, Issn: 1059-9495, 10.1007/s11665-011-0111-1, Volume 1 / 1992 – Volume 21 / 2012. Available online at Springer Link.
104-11 Fu-Yuan Hsu and Huey Jiuan Lin, Foam Filters Used in Gravity Casting, Metall and Materi Trans B (2011) 42: 1110. doi:10.1007/s11663-011-9548-8.
99-11 Eduardo Trejo, Centrifugal Casting of an Aluminium Alloy, thesis: Doctor of Philosophy, Metallurgy and Materials School of Engineering University of Birmingham, October 2011. Full paper available upon request.
71-11 Fu-Yuan Hsu and Yao-Ming Yang Confluence Weld in an Aluminum Gravity Casting, Journal of Materials Processing Technology, Available online 23 November 2011, ISSN 0924-0136, 10.1016/j.jmatprotec.2011.11.006.
46-11 Daniel Einsiedler, Entwicklung einer Simulationsmethodik zur Simulation von Strömungs- und Trocknungsvorgängen bei Kernfertigungsprozessen mittels CFD (Development of a simulation methodology for simulating flow and drying operations in core production processes using CFD), MSc thesis at Technical University of Aalen in Germany (Hochschule Aalen), 2011.
31-11 Johannes Hartmann, André Trepper, Carolin Körner, Aluminum Integral Foams with Near-Microcellular Structure, Advanced Engineering Materials, 13: n/a. doi: 10.1002/adem.201100035, June 2011.
21-11 Thang Nguyen, Vu Nguyen, Morris Murray, Gary Savage, John Carrig, Modelling Die Filling in Ultra-Thin Aluminium Castings, Materials Science Forum (Volume 690), Light Metals Technology V, pp 107-111, 10.4028/www.scientific.net/MSF.690.107, June 2011.
15-11 J. J. Hernández-Ortega, R. Zamora, J. López, and F. Faura, Numerical Analysis of Air Pressure Effects on the Flow Pattern during the Filling of a Vertical Die Cavity, AIP Conf. Proc., Volume 1353, pp. 1238-1243, The 14th International Esaform Conference on Material Forming: Esaform 2011; doi:10.1063/1.3589686, May 2011. Available online.
08-11 Hai Peng Li, Chun Yong Liang, Li Hui Wang, Hong Shui Wang, Numerical Simulation of Casting Process for Gray Iron Butterfly Valve, Advanced Materials Research, 189-193, 260, February 2011.
48-10 J. J. Hernández-Ortega, R. Zamora, J. Palacios, J. López and F. Faura, An Experimental and Numerical Study of Flow Patterns and Air Entrapment Phenomena During the Filling of a Vertical Die Cavity, J. Manuf. Sci. Eng., October 2010, Volume 132, Issue 5, 05101, doi:10.1115/1.4002535.
41-10 Pamela J. Waterman, Understanding Core-Gas Defects, Desktop Engineering, October 2010. Available online at Desktop Engineering. Also published in the Foundry Trade Journal, November 2010.
32-10 Guan Hai Yan, Sheng Dun Zhao, Zheng Hui Sha, Parameters Optimization of Semisolid Diecasting Process for Air-Conditioner’s Triple Valve in HPb59-1 Alloy, Advanced Materials Research (Volumes 129 – 131), Vol. Material and Manufacturing Technology, pp. 936-941, DOI: 10.4028/www.scientific.net/AMR.129-131.936, August 2010.
29-10 Zheng Peng, Xu Jun, Zhang Zhifeng, Bai Yuelong, and Shi Likai, Numerical Simulation of Filling of Rheo-diecasting A357 Aluminum Alloy, Special Casting & Nonferrous Alloys, DOI: CNKI:SUN:TZZZ.0.2010-01-024, 2010.
15-10 David H. Kirkwood, Michel Suery, Plato Kapranos, Helen V. Atkinson, and Kenneth P. Young, Semi-solid Processing of Alloys, 2010, XII, 172 p. 103 illus., 19 in color., Hardcover ISBN: 978-3-642-00705-7.
09-10 Shannon Wetzel, Fullfilling Da Vinci’s Dream, Modern Casting, April 2010.
08-10 B.I. Semenov, K.M. Kushtarov, Semi-solid Manufacturing of Castings, New Industrial Technologies, Publication of Moscow State Technical University n.a. N.E. Bauman, 2009 (in Russian)
07-10 Carl Reilly, Development Of Quantitative Casting Quality Assessment Criteria Using Process Modelling, thesis: The University of Birmingham, March 2010 (Available upon request)
60-09 Somlak Wannarumon, and Marco Actis Grande, Comparisons of Computer Fluid Dynamic Software Programs applied to Jewelry Investment Casting Process, World Academy of Science, Engineering and Technology 55 2009.
59-09 Marco Actis Grande and Somlak Wannarumon, Numerical Simulation of Investment Casting of Gold Jewelry: Experiments and Validations, World Academy of Science, Engineering and Technology, Vol:3 2009-07-24
51-09 In-Ting Hong, Huan-Chien Tung, Chun-Hao Chiu and Hung-Shang Huang, Effect of Casting Parameters on Microstructure and Casting Quality of Si-Al Alloy for Vacuum Sputtering, China Steel Technical Report, No. 22, pp. 33-40, 2009.
42-09 P. Väyrynen, S. Wang, S. Louhenkilpi and L. Holappa, Modeling and Removal of Inclusions in Continuous Casting, Materials Science & Technology 2009 Conference & Exhibition, Pittsburgh, Pennsylvania, USA, October 25-29, 2009
7-09 Andrei Starobin, Simulation of Core Gas Evolution and Flow, presented at the North American Die Casting Association – 113th Metalcasting Congress, April 7-10, 2009, Las Vegas, Nevada, USA
6-09 A.Pari, Optimization of HPDC PROCESS: Case Studies, North American Die Casting Association – 113th Metalcasting Congress, April 7-10, 2009, Las Vegas, Nevada, USA
09-07 Alexandre Reikher and Michael Barkhudarov, Casting: An Analytical Approach, Springer, 1st edition, August 2007, Hardcover ISBN: 978-1-84628-849-4. U.S. Order Form; Europe Order Form.
02-07 Fu-Yuan Hsu, Mark R. Jolly and John Campbell, The Design of L-Shaped Runners for Gravity Casting, Shape Casting: 2nd International Symposium, Edited by Paul N. Crepeau, Murat Tiryakioðlu and John Campbell, TMS (The Minerals, Metals & Materials Society), Orlando, FL, Feb 2007
6-06 M. Barkhudarov, and G. Wei, Modeling of the Coupled Motion of Rigid Bodies in Liquid Metal, Modeling of Casting, Welding and Advanced Solidification Processes – XI, May 28 – June 2, 2006, Opio, France, eds. Ch.-A. Gandin and M. Bellet, pp 71-78, 2006.
2-06 J.-C. Gebelin, M.R. Jolly and F.-Y. Hsu, ‘Designing-in’ Controlled Filling Using Numerical Simulation for Gravity Sand Casting of Aluminium Alloys, Int. J. Cast Met. Res., 2006, Vol.19 No.1
30-05 H. Xue, K. Kabiri-Bamoradian, R.A. Miller, Modeling Dynamic Cavity Pressure and Impact Spike in Die Casting, Cast Expo ’05, April 16-19, 2005
22-05 Blas Melissari & Stavros A. Argyropoulous, Measurement of Magnitude and Direction of Velocity in High-Temperature Liquid Metals; Part I, Mathematical Modeling, Metallurgical and Materials Transactions B, Volume 36B, October 2005, pp. 691-700
21-05 M.R. Jolly, State of the Art Review of Use of Modeling Software for Casting, TMS Annual Meeting, Shape Casting: The John Campbell Symposium, Eds, M. Tiryakioglu & P.N Crepeau, TMS, Warrendale, PA, ISBN 0-87339-583-2, Feb 2005, pp 337-346
20-05 J-C Gebelin, M.R. Jolly & F-Y Hsu, ‘Designing-in’ Controlled Filling Using Numerical Simulation for Gravity Sand Casting of Aluminium Alloys, TMS Annual Meeting, Shape Casting: The John Campbell Symposium, Eds, M. Tiryakioglu & P.N Crepeau, TMS, Warrendale, PA, ISBN 0-87339-583-2, Feb 2005, pp 355-364
19-05 F-Y Hsu, M.R. Jolly & J Campbell, Vortex Gate Design for Gravity Castings, TMS Annual Meeting, Shape Casting: The John Campbell Symposium, Eds, M. Tiryakioglu & P.N Crepeau, TMS, Warrendale, PA, ISBN 0-87339-583-2, Feb 2005, pp 73-82
18-05 M.R. Jolly, Modelling the Investment Casting Process: Problems and Successes, Japanese Foundry Society, JFS, Tokyo, Sept. 2005
6-05 Birgit Hummler-Schaufler, Fritz Hirning, Jurgen Schaufler, A World First for Hatz Diesel and Schaufler Tooling, Die Casting Engineer, May 2005, pp. 18-21
4-05 Rolf Krack, The W35 Topic—A World First, Die Casting World, March 2005, pp. 16-17
36-04 Ik Min Park, Il Dong Choi, Yong Ho Park, Development of Light-Weight Al Scroll Compressor for Car Air Conditioner, Materials Science Forum, Designing, Processing and Properties of Advanced Engineering Materials, 449-452, 149, March 2004.
30-04 Haijing Mao, A Numerical Study of Externally Solidified Products in the Cold Chamber Die Casting Process, thesis: The Ohio State University, 2004 (Available upon request)
23-04State of the Art Use of Computational Modelling in the Foundry Industry, 3rd International Conference Computational Modelling of Materials III, Sicily, Italy, June 2004, Advances in Science and Technology, Eds P. Vincenzini & A Lami, Techna Group Srl, Italy, ISBN: 88-86538-46-4, Part B, pp 479-490
22-04 Jerry Fireman, Computer Simulation Helps Reduce Scrap, Die Casting Engineer, May 2004, pp. 46-49
21-04 Joerg Frei, Simulation—A Safe and Quick Way to Good Components, Aluminium World, Volume 3, Issue 2, pp. 42-43
14-04 Sayavur I. Bakhtiyarov, Charles H. Sherwin, and Ruel A. Overfelt, Hot Distortion Studies In Phenolic Urethane Cold Box System, American Foundry Society, 108th Casting Congress, June 12-15, 2004, Rosemont, IL, USA
13-04 Sayavur I. Bakhtiyarov and Ruel A. Overfelt, First V-Process Casting of Magnesium, American Foundry Society, 108th Casting Congress, June 12-15, 2004, Rosemont, IL, USA
5-04 C. Schlumpberger & B. Hummler-Schaufler, Produktentwicklung auf hohem Niveau (Product Development on a High Level), Druckguss Praxis, January 2004, pp 39-42 (in German).
3-04 Charles Bates, Dealing with Defects, Foundry Management and Technology, February 2004, pp 23-25
1-04 Laihua Wang, Thang Nguyen, Gary Savage and Cameron Davidson, Thermal and Flow Modeling of Ladling and Injection in High Pressure Die Casting Process, International Journal of Cast Metals Research, vol. 16 No 4 2003, pp 409-417
21-03 E F Brush Jr, S P Midson, W G Walkington, D T Peters, J G Cowie, Porosity Control in Copper Rotor Die Castings, NADCA Indianapolis Convention Center, Indianapolis, IN September 15-18, 2003, T03-046
10-03 Gebelin., J-C and Jolly, M.R., Modeling of the Investment Casting Process, Journal of Materials Processing Tech., Vol. 135/2-3, pp. 291 – 300
9-03 Cox, M, Harding, R.A. and Campbell, J., Optimised Running System Design for Bottom Filled Aluminium Alloy 2L99 Investment Castings, J. Mat. Sci. Tech., May 2003, Vol. 19, pp. 613-625
8-03 Von Alexander Schrey and Regina Reek, Numerische Simulation der Kernherstellung, (Numerical Simulation of Core Blowing), Giesserei, June 2003, pp. 64-68 (in German)
7-03 J. Zuidema Jr., L Katgerman, Cyclone separation of particles in aluminum DC Casting, Proceedings from the Tenth International Conference on Modeling of Casting, Welding and Advanced Solidification Processes, Destin, FL, May 2003, pp. 607-614
6-03 Jean-Christophe Gebelin and Mark Jolly, Numerical Modeling of Metal Flow Through Filters, Proceedings from the Tenth International Conference on Modeling of Casting, Welding and Advanced Solidification Processes, Destin, FL, May 2003, pp. 431-438
5-03 N.W. Lai, W.D. Griffiths and J. Campbell, Modelling of the Potential for Oxide Film Entrainment in Light Metal Alloy Castings, Proceedings from the Tenth International Conference on Modeling of Casting, Welding and Advanced Solidification Processes, Destin, FL, May 2003, pp. 415-422
21-02 Boris Lukezic, Case History: Process Modeling Solves Die Design Problems, Modern Casting, February 2003, P 59
16-02 Barkhudarov, Michael, Computer Simulation of Lost Foam Process, Casting Simulation Background and Examples from Europe and the USA, World Foundrymen Organization, 2002, pp 319-324
15-02 Barkhudarov, Michael, Computer Simulation of Inclusion Tracking, Casting Simulation Background and Examples from Europe and the USA, World Foundrymen Organization, 2002, pp 341-346
14-02 Barkhudarov, Michael, Advanced Simulation of the Flow and Heat Transfer of an Alternator Housing, Casting Simulation Background and Examples from Europe and the USA, World Foundrymen Organization, 2002, pp 219-228
7-02 A Habibollah Zadeh, and J Campbell, Metal Flow Through a Filter System, University of Birmingham, 2002 American Foundry Society, AFS Transactions 02-020, Kansas City, MO
6-02 Phil Ward, and Helen Atkinson, Final Report for EPSRC Project: Modeling of Thixotropic Flow of Metal Alloys into a Die, GR/M17334/01, March 2002, University of Sheffield
5-02 S. I. Bakhtiyarov and R. A. Overfelt, Numerical and Experimental Study of Aluminum Casting in Vacuum-sealed Step Molding, Auburn University, 2002 American Foundry Society, AFS Transactions 02-050, Kansas City, MO
4-02 J. C. Gebelin and M. R. Jolly, Modelling Filters in Light Alloy Casting Processes, University of Birmingham, 2002 American Foundry Society AFS Transactions 02-079, Kansas City, MO
3-02 Mark Jolly, Mike Cox, Jean-Christophe Gebelin, Sam Jones, and Alex Cendrowicz, Fundamentals of Investment Casting (FOCAST), Modelling the Investment Casting Process, Some preliminary results from the UK Research Programme, IRC in Materials, University of Birmingham, UK, AFS2001
49-01 Hua Bai and Brian G. Thomas, Bubble formation during horizontal gas injection into downward-flowing liquid, Metallurgical and Materials Transactions B, Vol. 32, No. 6, pp. 1143-1159, 2001. doi.org/10.1007/s11663-001-0102-y
45-01 Jan Zuidema; Laurens Katgerman; Ivo J. Opstelten;Jan M. Rabenberg, Secondary Cooling in DC Casting: Modelling and Experimental Results, TMS 2001, New Orleans, Louisianna, February 11-15, 2001
43-01 James Andrew Yurko, Fluid Flow Behavior of Semi-Solid Aluminum at High Shear Rates,Ph.D. thesis; Massachusetts Institute of Technology, June 2001. Abstract only; full thesis available at http://dspace.mit.edu/handle/1721.1/8451 (for a fee).
33-01 Juang, S.H., CAE Application on Design of Die Casting Dies, 2001 Conference on CAE Technology and Application, Hsin-Chu, Taiwan, November 2001, (article in Chinese with English-language abstract)
32-01 Juang, S.H. and C. M. Wang, Effect of Feeding Geometry on Flow Characteristics of Magnesium Die Casting by Numerical Analysis, The Preceedings of 6th FADMA Conference, Taipei, Taiwan, July 2001, Chinese language with English abstract
21-01 P. Scarber Jr., Using Liquid Free Surface Areas as a Predictor of Reoxidation Tendency in Metal Alloy Castings, presented at the Steel Founders’ Society of American, Technical and Operating Conference, October 2001
20-01 P. Scarber Jr., J. Griffin, and C. E. Bates, The Effect of Gating and Pouring Practice on Reoxidation of Steel Castings, presented at the Steel Founders’ Society of American, Technical and Operating Conference, October 2001
18-01 Rajiv Shivpuri, Venkatesh Sankararaman, Kaustubh Kulkarni, An Approach at Optimizing the Ingate Design for Reducing Filling and Shrinkage Defects, The Ohio State University, Columbus, OH, Presented by North American Die Casting Association, Oct 29-Nov 1, 2001, Cincinnati, TO1-052
2-01 J. Grindling, Customized CFD Codes to Simulate Casting of Thermosets in Full 3D, Electrical Manufacturing and Coil Winding 2000 Conference, October 31-November 2, 20
20-00 Richard Schuhmann, John Carrig, Thang Nguyen, Arne Dahle, Comparison of Water Analogue Modelling and Numerical Simulation Using Real-Time X-Ray Flow Data in Gravity Die Casting, Australian Die Casting Association Die Casting 2000 Conference, September 3-6, 2000, Melbourne, Victoria, Australia
15-00 M. Sirvio, Vainola, J. Vartianinen, M. Vuorinen, J. Orkas, and S. Devenyi, Fluid Flow Analysis for Designing Gating of Aluminum Castings, Proc. NADCA Conf., Rosemont, IL, Nov 6-8, 1999
14-00 X. Yang, M. Jolly, and J. Campbell, Reduction of Surface Turbulence during Filling of Sand Castings Using a Vortex-flow Runner, Conference for Modeling of Casting, Welding, and Advanced Solidification Processes IX, Aachen, Germany, August 2000
13-00 H. S. H. Lo and J. Campbell, The Modeling of Ceramic Foam Filters, Conference for Modeling of Casting, Welding, and Advanced Solidification Processes IX, Aachen, Germany, August 2000
12-00 M. R. Jolly, H. S. H. Lo, M. Turan and J. Campbell, Use of Simulation Tools in the Practical Development of a Method for Manufacture of Cast Iron Camshafts,” Conference for Modeling of Casting, Welding, and Advanced Solidification Processes IX, Aachen, Germany, August, 2000
14-99 J Koke, and M Modigell, Time-Dependent Rheological Properties of Semi-solid Metal Alloys, Institute of Chemical Engineering, Aachen University of Technology, Mechanics of Time-Dependent Materials 3: 15-30, 1999
12-99 Grun, Gerd-Ulrich, Schneider, Wolfgang, Ray, Steven, Marthinusen, Jan-Olaf, Recent Improvements in Ceramic Foam Filter Design by Coupled Heat and Fluid Flow Modeling, Proc TMS Annual Meeting, 1999, pp. 1041-1047
10-99 Bongcheol Park and Jerald R. Brevick, Computer Flow Modeling of Cavity Pre-fill Effects in High Pressure Die Casting, NADCA Proceedings, Cleveland T99-011, November, 1999
8-99 Brad Guthrie, Simulation Reduces Aluminum Die Casting Cost by Reducing Volume, Die Casting Engineer Magazine, September/October 1999, pp. 78-81
19-98 Grun, Gerd-Ulrich, & Schneider, Wolfgang, Numerical Modeling of Fluid Flow Phenomena in the Launder-integrated Tool Within Casting Unit Development, Proc TMS Annual Meeting, 1998, pp. 1175-1182
18-98 X. Yang & J. Campbell, Liquid Metal Flow in a Pouring Basin, Int. J. Cast Metals Res, 1998, 10, pp. 239-253
15-98 R. Van Tol, Mould Filling of Horizontal Thin-Wall Castings, Delft University Press, The Netherlands, 1998
14-98 J. Daughtery and K. A. Williams, Thermal Modeling of Mold Material Candidates for Copper Pressure Die Casting of the Induction Motor Rotor Structure, Proc. Int’l Workshop on Permanent Mold Casting of Copper-Based Alloys, Ottawa, Ontario, Canada, Oct. 15-16, 1998
10-98 C. W. Hirt, and M.R. Barkhudarov, Lost Foam Casting Simulation with Defect Prediction, Flow Science Inc, presented at Modeling of Casting, Welding and Advanced Solidification Processes VIII Conference, June 7-12, 1998, Catamaran Hotel, San Diego, California
9-98 M. R. Barkhudarov and C. W. Hirt, Tracking Defects, Flow Science Inc, presented at the 1st International Aluminum Casting Technology Symposium, 12-14 October 1998, Rosemont, IL
3-98 P. Kapranos, M. R. Barkhudarov, D. H. Kirkwood, Modeling of Structural Breakdown during Rapid Compression of Semi-Solid Alloy Slugs, Dept. Engineering Materials, The University of Sheffield, Sheffield S1 3JD, U.K. and Flow Science Inc, USA, Presented at the 5th International Conference Semi-Solid Processing of Alloys and Composites, Colorado School of Mines, Golden, CO, 23-25 June 1998
1-98 U. Jerichow, T. Altan, and P. R. Sahm, Semi Solid Metal Forming of Aluminum Alloys-The Effect of Process Variables Upon Material Flow, Cavity Fill and Mechanical Properties, The Ohio State University, Columbus, OH, published in Die Casting Engineer, p. 26, Jan/Feb 1998
8-97 Michael Barkhudarov, High Pressure Die Casting Simulation Using FLOW-3D, Die Casting Engineer, 1997
14-97 M. Ranganathan and R. Shivpuri, Reducing Scrap and Increasing Die Life in Low Pressure Die Casting through Flow Simulation and Accelerated Testing, Dept. Welding and Systems Engineering, Ohio State University, Columbus, OH, presented at 19th International Die Casting Congress & Exposition, November 3-6, 1997
13-97 J. Koke, Modellierung und Simulation der Fließeigenschaften teilerstarrter Metallegierungen, Livt Information, Institut für Verfahrenstechnik, RWTH Aachen, October 1997
8-97 H. Grazzini and D. Nesa, Thermophysical Properties, Casting Simulation and Experiments for a Stainless Steel, AT Systemes (Renault) report, presented at the Solidification Processing ’97 Conference, July 7-10, 1997, Sheffield, U.K.
7-97 R. Van Tol, L. Katgerman and H. E. A. Van den Akker, Horizontal Mould Filling of a Thin Wall Aluminum Casting, Laboratory of Materials report, Delft University, presented at the Solidification Processing ’97 Conference, July 7-10, 1997, Sheffield, U.K.
22-96 Grun, Gerd-Ulrich & Schneider, Wolfgang, 3-D Modeling of the Start-up Phase of DC Casting of Sheet Ingots, Proc TMS Annual Meeting, 1996, pp. 971-981
4-96 C. W. Hirt, A Computational Model for the Lost Foam Process, Flow Science final report, February 1996 (FSI-96-57-R2)
3-96 M. R. Barkhudarov, C. L. Bronisz, C. W. Hirt, Three-Dimensional Thixotropic Flow Model, Flow Science report, FSI-96-00-1, published in the proceedings of (pp. 110- 114) and presented at the 4th International Conference on Semi-Solid Processing of Alloys and Composites, The University of Sheffield, 19-21 June 1996
1-96 M. R. Barkhudarov, J. Beech, K. Chang, and S. B. Chin, Numerical Simulation of Metal/Mould Interfacial Heat Transfer in Casting, Dept. Mech. & Process Engineering, Dept. Engineering Materials, University of Sheffield and Flow Science Inc, 9th Int. Symposium on Transport Phenomena in Thermal-Fluid Engineering, June 25-28, 1996, Singapore
10-95 Grun, Gerd-Ulrich, & Schneider, Wolfgang, Optimal Design of a Distribution Pan for Level Pour Casting, Proc TMS Annual Meeting, 1995, pp. 1061-1070
9-95 E. Masuda, I. Itoh, K. Haraguchi, Application of Mold Filling Simulation to Die Casting Processes, Honda Engineering Co., Ltd., Tochigi, Japan, presented at the Modelling of Casting, Welding and Advanced Solidification Processes VII, The Minerals, Metals & Materials Society, 1995
6-95 K. Venkatesan, Experimental and Numerical Investigation of the Effect of Process Parameters on the Erosive Wear of Die Casting Dies, presented for Ph.D. degree at Ohio State University, 1995
5-95 J. Righi, A. F. LaCamera, S. A. Jones, W. G. Truckner, T. N. Rouns, Integration of Experience and Simulation Based Understanding in the Die Design Process, Alcoa Technical Center, Alcoa Center, PA 15069, presented by the North American Die Casting Association, 1995
2-95 K. Venkatesan and R. Shivpuri, Numerical Simulation and Comparison with Water Modeling Studies of the Inertia Dominated Cavity Filling in Die Casting, NUMIFORM, 1995
13-94 Deniece Korzekwa and Paul Dunn, A Combined Experimental and Modeling Approach to Uranium Casting, Materials Division, Los Alamos National Laboratory, presented at the Symposium on Liquid Metal Processing and Casting, El Dorado Hotel, Santa Fe, New Mexico, 1994
12-94 R. van Tol, H. E. A. van den Akker and L. Katgerman, CFD Study of the Mould Filling of a Horizontal Thin Wall Aluminum Casting, Delft University of Technology, Delft, The Netherlands, HTD-Vol. 284/AMD-Vol. 182, Transport Phenomena in Solidification, ASME 1994
11-94 M. R. Barkhudarov and K. A. Williams, Simulation of ‘Surface Turbulence’ Fluid Phenomena During the Mold Filling Phase of Gravity Castings, Flow Science Technical Note #41, November 1994 (FSI-94-TN41)
16-93 K. Venkatesan and R. Shivpuri, Numerical Simulation of Die Cavity Filling in Die Castings and an Evaluation of Process Parameters on Die Wear, Dept. of Industrial Systems Engineering, Presented by: N.A. Die Casting Association, Cleveland, Ohio, October 18-21, 1993
15-93 K. Venkatesen and R. Shivpuri, Numerical Modeling of Filling and Solidification for Improved Quality of Die Casting: A Literature Survey (Chapters II and III), Engineering Research Center for Net Shape Manufacturing, Report C-93-07, August 1993, Ohio State University
1-93 P-E Persson, Computer Simulation of the Solidification of a Hub Carrier for the Volvo 800 Series, AB Volvo Technological Development, Metals Laboratory, Technical Report No. LM 500014E, Jan. 1993
13-92 D. R. Korzekwa, M. A. K. Lewis, Experimentation and Simulation of Gravity Fed Lead Castings, in proceedings of a TMS Symposium on Concurrent Engineering Approach to Materials Processing, S. N. Dwivedi, A. J. Paul and F. R. Dax, eds., TMS-AIME Warrendale, p. 155 (1992)
12-92 M. A. K. Lewis, Near-Net-Shaiconpe Casting Simulation and Experimentation, MST 1992 Review, Los Alamos National Laboratory
2-92 M. R. Barkhudarov, H. You, J. Beech, S. B. Chin, D. H. Kirkwood, Validation and Development of FLOW-3D for Casting, School of Materials, University of Sheffield, Sheffield, UK, presented at the TMS/AIME Annual Meeting, San Diego, CA, March 3, 1992
1-92 D. R. Korzekwa and L. A. Jacobson, Los Alamos National Laboratory and C.W. Hirt, Flow Science Inc, Modeling Planar Flow Casting with FLOW-3D, presented at the TMS/AIME Annual Meeting, San Diego, CA, March 3, 1992
12-91 R. Shivpuri, M. Kuthirakulathu, and M. Mittal, Nonisothermal 3-D Finite Difference Simulation of Cavity Filling during the Die Casting Process, Dept. Industrial and Systems Engineering, Ohio State University, presented at the 1991 Winter Annual ASME Meeting, Atlanta, GA, Dec. 1-6, 1991
11-90 N. Saluja, O.J. Ilegbusi, and J. Szekely, On the Calculation of the Electromagnetic Force Field in the Circular Stirring of Metallic Melts, accepted in J. Appl. Physics, 1990
10-90 N. Saluja, O. J. Ilegbusi, and J. Szekely, On the Calculation of the Electromagnetic Force Field in the Circular Stirring of Metallic Molds in Continuous Castings, presented at the 6th Iron and Steel Congress of the Iron and Steel Institute of Japan, Nagoya, Japan, October 1990
9-90 N. Saluja, O. J. Ilegbusi, and J. Szekely, Fluid Flow in Phenomena in the Electromagnetic Stirring of Continuous Casting Systems, Part I. The Behavior of a Cylindrically Shaped, Laboratory Scale Installation, accepted for publication in Steel Research, 1990
8-89 C. W. Hirt, Gravity-Fed Casting, Flow Science Technical Note #20, July 1989 (FSI-89-TN20)
6-89 E. W. M. Hansen and F. Syvertsen, Numerical Simulation of Flow Behaviour in Moldfilling for Casting Analysis, SINTEF-Foundation for Scientific and Industrial Research at the Norwegian Institute of Technology, Trondheim, Norway, Report No. STS20 A89001, June 1989
1-88 C. W. Hirt and R. P. Harper, Modeling Tests for Casting Processes, Flow Science report, Jan. 1988 (FSI-88-38-01)
2-87 C. W. Hirt, Addition of a Solidification/Melting Model to FLOW-3D, Flow Science report, April 1987 (FSI-87-33-1)
Continuous Casting Workspace는 연속형 빌릿 주조 및 직접 냉간 연속 주조 등 일반적으로 사용되는 모든 주조 공장 공정을 시뮬레이션할 수 있는 사용하기 쉬운 도구를 지속적으로 주조 사용자에게 제공합니다. 새로운 Continuous Casting Workspace를 통해 사용자는 연속 주조 공정을 모델링하고 공정 파라미터를 최적화하는 데 필요한 도구를 찾을 수 있습니다.
멀티 블록 메쉬는 주조물의 높은 전단 및 고온 구배 영역에서 훨씬 더 높은 정확도를 제공하는 효율적인 방법을 제공합니다. Mold 및 Billlet 냉각, 용해 유량, 과열 및 Mold 형상과 같은 공정 매개변수가 분석에 포함됩니다. 용탕 표면의 운동과 몰드의 온동은 후처리 중에 빠르게 시각화되며, 이 과정에서 충진 및 응고 패턴도 쉽게 평가되므로 공정 수정을 자신 있게 구현할 수 있습니다.
연속 주조는 용강이 반제품 빌렛, 블룸 또는 슬래브로 응고되어 후속 압연기에서 압연하는 공정입니다. 연속 주조시, 용강은 레들에서 주조기로 이송됩니다. 주조 작업이 시작되면 레들의 바닥에 있는 슬라이딩 셔터가 열리고 철강은 제어된 속도로 턴디쉬 안으로 그리고 턴디쉬에서 하나 이상의 주형으로 흐릅니다.
1950 년대에 연속 주조가 도입되기 전에 철강은 고정 금형에 붓고 잉곳을 성형했습니다. 그 이후로 지속적인 주조는 수율, 품질, 생산성 및 비용 효율성을 향상시키기 위해 발전해 왔습니다. 주조 회사는 공정 개선을 위해 항상 노력하고 있으며, FLOW-3D CAST를 사용한 시뮬레이션은 물리적 시행 착오없이 비용을 절감할 수 있는 기회를 제공합니다.
Semi-Continuous Casting of a 600 mm Slab with Stress Calculation
이 시뮬레이션에서는 600mm직경 슬래브의 반 연속 주조의 공정이 모델링 됩니다. 액체 금속, A7050 합금은 세라믹 노즐을 통해 상단에서 들어가 흑연 주형을 통과하고, 표면 열전달계수와 지정된 온도로 모델링 된 물 분무에 의해 냉각됩니다. 하단의 강철 캡은 금속의 이동을 시작하여 액체 금속이 유출되는 것을 방지합니다. 캡은 0.3mm/sec의 일정한 속도로 아래쪽으로 이동하는 General Moving Object 물리 모델로 모델링 됩니다. 열응력 해석 모델은 균일하지 않은 냉각 및 수축으로 인해 고상 금속에서 발생하는 응력 및 변형을 예측하는 데 사용됩니다. 이 애니메이션은 Von Mises stress 결과를 보여 주는데, 400배로 확대된 결과입니다.
Continuous Casting Simulations
Rotational channel continuous casting example.
Solid fraction contours of the continuous casting process of a cylindrical steed rod using the general moving object and solidification models.
A 2D axisymmetric slice showing transient solidification contours through the transition region during continuous casting of a cylindrical steel rod.
응고 모델은 열전달이 활성화되고(Physics → Heat Transfer → Fluid internal energy advection) 유체비열(Fluids → Fluid 1 → Thermal Properties → Specific heat)과 전도도(Fluids → Fluid 1 → Thermal Properties → Thermal Conductivity) 이 지정될 때 사용될 수 있다. 단지 유체 1만 상 변화를 겪을 수 있다.
응고모델을 활성화하기 위해 Fluids → Fluid 1 → Solidification Model 을 체크하고 물성 Fluids → Fluid 1 → Solidification Model 가지에서 Liquidus temperature, Solidus temperature, 그리고 Latent heat of fusion 를 지정한다. 가장 간단한 모델(Latent Heat Release Definition 에 펼쳐지는 메뉴에서 Linearly with constant 를 선택)에서, 잠열은 물체가 Liquidus 에서 Solidus 온도로 냉각될 때 선형적으로 방출된다. 고상에서의 상변화열을 포함하는, 잠열 방출의 더 자세한 모델을 위해 온도의 함수로 잠열방출을 정의하기 위해 Specific energy vs. temperature 또는 Solid fraction vs. temperature 선택을 사용한다. 이 지정에 대한 더 자세한 내용은 이론 매뉴얼의 Heat of Transformation 를 참조한다.
응고는 유체의 강직성 및 유동저항을 뜻한다. 이 강직성은 두 가지로 모델링 된다. 낮은 고상율에 대해 즉 Fluids → Fluid 1 → Solidification Model → Solidified Fluid 1 Properties → Coherent Solid Fraction 의 coherency 점 밑에서는 점도는 고상율의 함수이다. 간섭 고상율보다 큰 고상율에 대해서는 고상율의 함수에 비례하는 항력계수를 갖는 Darcy 형태의 항력이 이용된다. 이 항력은 모멘텀 방정식에 (bx,by,bz) 로써 추가된다- Momentum Equations 를 보라. 이 항력의 계산은 Solidification Drag Model 에서 기술된다. 항력계수는 사용자가 유동저항에 양을 조절할 수 있는 Coefficient of Solidification Drag 인자를 포함한다. 항력계수는 FLOW-3D 출력에서 기록된 속도에 상응하는 지역 상 평균 속도에 의해 곱해진다.
Fluid 1 Properties)을 지나면 항력은 무한대가 되고 계산격자 관련하여 유동이 있을 수 없다(단 예외로 Moving Solid Phase를 참조).
Note
모든 유체가 완전히 응고하면 모사를 정지시키기 위해 General → Finish condition → Solidified fluid fraction 를 이용한다. General → Finish condition → Finish fraction 은 모사를 중지하기 위한 고상율 값을 정한다.
주조 시 mushy zone 은 액상과 고상이 혼합물로 존재하는 지역이다. 이 지역 혼합점도는 동축의 수지상 조직(과냉각된 액체 안에서 방사상으로 자라는 결정으로 된 구조) 이 액체 안에서 자유롭게 부유할 때 영향을 미친다.
일단 수지상 조직의 간섭성이 발생하여 고정된 고상 망이 형성되면 액상이 고정된 다공 수지상 구조를 통과해야 하므로 추가의 유동손실이 발생한다. 다른 방법으로는 간섭점을 지난 액/고상 혼합물은 다공물질을 통한 유동 대신에 고점도의 유체로 간주될 수 있다. 점성유체로 간주하는 접근은 예를 들면 연속 이중 롤 주조 과정같이 고상이 계속 이동 및 변형할 때 유용하다.
Solidification Drag Models in FLOW-3D, FLOW-3D 내 응고 항력모델
응고에 의한 항력계수를 정의하기 위해 사용자는 우선 열전달 및 응고모델을 활성화 해야 한다. 이들은 Model Setup → Physics 탭 에서 활성화될 수 있다. 수축모델 또한 응고모델 창에서 활성화될 수 있다.
일단 Solidification 모델이 활성화되면 항력의 공식이 지정될 필요가 있다. Solidification대화의 밑 좌측 모퉁이에서 Porous media drag-based 와 Viscosity-based 의 항력공식 중의 선택을 한다.
Viscosity-based 공식은 점성 유체로 취급하며 Viscosity 영역 내Flow model for solidified metal 입력 밑에서 지정되는 순수 고상 점성을 갖는 고상화된 유체로 간주된다. 이 접근법은 경직성의 항력모델(즉, 응고 금속이 롤러 사이로 압착될 때)을 사용할 수 없는 경우의 모사에 이용된다. 이 점성은 고상율에 따라 선형으로 변한다.고상율이0일 때 점도는 유체1의 점도이다.고상율이1이면 점도는 Solidification 패널에서 지정된 값과 같다.
Porous media drag-based 공식은 응고상태를 결정하기 위해 고상율을 사용한다. 고상율이 Critical Solid Fraction 이거나 초과하면 이때 항력은 무한대가 된다-즉, 액상/고상 혼합물은 고체같이 거동한다. 고상율이 Coherent Solid Fraction 보다 작으면 항력은 0이다. 이 두 값 사이에서 유동은 mushy 지역에 있고 이를 통한 유동은 마치 다공질 내에서의 유동같이 처리된다. 또한 모델은 고상율이 Coherent Solid Fraction 보다 작을 때 자동적으로 용융 금속의 점도를 조절한다. 이 상태에서 고상결정은 점도를 올리지만 결합하지는 않는다(즉, 간섭 없음). 일단 유체가 Coherent Solid Fraction 에 도달하면 항력방정식이 고려되고 점도는 간섭성에 도달하기 전의 값으로 일정하게 된다. 임계 및 간섭 고상율은 사용자가 정의하며 논문이나 책 등에서 찾을 수 있다. 이 식에서는 Coefficient of Solidification Drag 가 정의되어야 한다. 이는 Solidification 창 또는 Fluid 1 → Solidification Model→Solidified Fluid 1 Properties tree → Other 트리를열어 Model Setup →Fluids 탭에서 될 수 있다.
How to Calculate Permeability 투과성 계산법
밑에 주어진 Darcy법칙은 수지상 구조를 위한 다공매질내의 수학적 유동기술이다.[Poi87].
(19)
여기서 u 는 수지상 구조 내 유동의 속도이고 ∇P 는 지역 압력구배, 그리고 K 는 mushy 구역의 특정 투수성이다. 이 방정식은 단지 유동이 거의 정상 상태이고, 관성효과가 없으며 유체의 체적율이 일정하고 균일하며 액체-액체의 상호작용 힘이 없을 때 유효하다. 투수성을 정의하는데 이용될 수 있는 대 여섯 개의 모델이 있으나 FLOW-3D 는 밑에 보여주는 Blake-Kozeny 을 이용한다. 다른 모델들은 코드와 함께 제공되는 소스코드를 사용자 사양에 맞게 수정하여 추가할 수 있다.
(20)
여기서
C2 는 전형적으로 와 같은 비틀림
fs 는 고상율이고
λ1는 유동을 위한 특정 치수
이 응용에서 수지상 가지 간격(DAS)이 이용된다.
식 (11.19) 을 식(11.20) 에 적용하면 투수성을 위한 다음 식을 얻는다.
(21)
수지상 가지 간격(DAS)에 대한 일반적인 값들은 밑에 주어져 있다.
Range of Cooling Rates in Solidification Processes¶
COOLING RATE, K/s
PRODUCTION PROCESSES
DENDRITE ARM SPACING,
to
large castings
5000 to 200
to
small castings, continuous castings, die castings, strip castings, coarse powder atomization
200 to 5
to
fine powder atomization, melt spinning, spray deposition, electron beam or laser surface melting
5 to 0.05
Range of cooling rates in solidification processes [CF85]
How FLOW-3D Defines the Coefficient of Solidification Drag FLOW-3D 가 응고 항력계수를 결정하는법
FLOW-3D 는 액고상 변화를 모델링하기 위해 다공매질항력을 이용한다. 항력은 고상율의 함수이다. 사용자에게 두 수축모델이 이용 가능하다; 급속 수축 모델 과 완전 유동모델. 급속 수축 모델은 상변화와 연관된 체적변화를 고려하지 않으며 유체는 정지해 있다고 가정한다. 완전 유동모델은 상변화가 관련된 체적변화를 고려한다. 항력은 투수성에 역으로 비례하므로 다음과 같이 표현될 수 있다.
(22)
여기서, Fd 는 FLOW-3D 에서 사용된 항력계수이다. 이 항력계수는 지역 속도에 의해 곱해지고 모멘텀 방정식의 오른쪽에서 차감된다 (Momentum Equations 참조). 식 (11.22) 를 재정리하고 식 (11.21) 로부터의 투수성에 치환하면 다음을 얻는다.
Macro-Segregation during Alloy Solidification 합금응고시 거시적 편절
편절 모델은 대류와 확산에 의한 용질 이동에 따른 이원합금 요소에서의 변화를 모델링 하도록 되어 있다. 이 모델링은 Physics → Solidification 로 부터 될 수 있다.
Activate binary alloy segregation model 을 체크하고 편절 모델을 활성화한다.
여러 온도에서 평형에 있는2원합금 요소농도를 정의하는 상태도는 직선의 고상선 및 액상선을 가진다고 가정된다. 상태도는 입력데이터에 의해 구성되고 전처리 그림파일 prpplt 에 포함된다. Analyze → Existing 에서 이용 가능하다
Macro-Segregation Model (under Fluids → Fluid 1 → Solidification Model)에 관련된 일부 유체물성 트리가 밑에 보여진다. 상태도는 Reference Solute Concentration 에서의 the Solidus 와 Liquidus Temperatures 값들에 의해 정의된다. 추가로 Concentration Variables 밑의 Partition coefficient 도 정의되어야 한다. 그렇지 않으면 Pure Solvent Melting Temperature 가 정의될 수 있다. Partition coefficient 와 Pure Solvent Melting Temperature 둘 다가 지정되면 용매 용융 온도는 상태도로부터 재 정의된다.
Eutectic Temperature 또는 Eutectic Concentration 는 융해작용을 정의하기 위해 지정될 수 있다. 또 이 두 변수가 다 지정되면 Eutectic Concentration 은 상태도에서 재 정의된다.
Diffusion Coefficients 는 고상과 액상 사이의 용질의 확산계수 비율을 정의한다. 액체 내의 용질의 분자 확산계수는 Physics → Solidification 에서 specifying Solute diffusion coefficient 를 지정함으로써 정해진다. RMSEG 는 용질의 난류 확산계수 승수를 정의한다; 이는 입력파일에서 직접 지정된다.
용질 재 분배에 의한 농도변화가 중요하면 Physics → Density evaluation → Density evaluated as a function of other quantities를 정하고 용질농도의 선형함수로써 금속농도를 정의하기 위해 Fluids → Segregation model 밑의 Solutal Expansion Coefficient 를 용질 확장계수로 지정한다. 이 경우 Reference Solute Concentration 이 기준농도로 사용될 것이다. 추가로 Fluids → Fluid 1 → Density Properties → Volumetric Thermal Expansion 은 액체 내 열부력 효과를 참작하기 위해 지정될 수 있다(또한 Buoyant Flow참조).
초기 용질농도는 Meshing & Geometry → Initial → Global → Uniform alloy solute concentration 에서 지정될 수 있다. 불 균일한 초기 분포는 Alloy solute concentration 밑의 초기유체 구역 안에서 정의될 수 있다. 추가로 농도는 Initial Conditions: Region Values 에서 기술된 바와 같이 2차함수를 사용하는 부분을 편집하여 공간상의2차함수로 변화할 수 있다. 압력과속도 경계에서 용질 경계조건을 정하기 위해 Boundaries → Boundary face → Solute concentration 를 이용한다.
액상 및 고상 구성은 후처리에서 데이터 변환을 이용하여 그려질 수 있다. 용융 응고금속은 금속 내 용융의 질량 분율을 저장하는 SLDEUT 를 그림으로써 가시화될 수 있다.
액상 내 열구배가 크면 Physics → Heat Transfer → Second order monotonicity preserving 를 지정함으로써 더 나은 정확성을 위해 고차원 이류법을 사용한다.
mushy 지역에서의 유동손실은 수지상 가지 간격(DAS)의 함수인 Fluids → Fluid 1 → Solidification Model → Solidified Fluid 1 Properties → Coefficient of Solidification Drag 에 의해 조절된다. 후자는 이 모델에 의해 계산되지 않으므로 사용자는 Coefficient of Solidification Drag 를 지정해야 한다
Note
표준 응고모델 과는 달리 상태도상의 용융점을 지나 고상선을 외삽하여 정의되므로 여기서 응고선의 값은 음수일 수 있다.
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