Simulation of Solidification Time of Commercially Pure Aluminium Casting in Metallic Moulds

Abstract

Solidification of metals poses many practical problems associated with phase transformation, shrinkage and heat transfer processes. Evaluation of solidification time is one of the important parameters used for assessing the properties of the metal castings. A mathematical model based on the control volume method with fixed mesh was selected in order to simulate the solidification of cast aluminium in permanent steel moulds. A mathematical model was developed which allowed obtaining of solidification time and the temperature fields at any time during solidification of commercially pure aluminium casting and in the metallic mould. An experimental casting of commercially pure aluminium was carried out in rectangular metallic mould. The temperature fields in both the cast and the mould to a very high accuracy were recorded using RD8600 digital temperature recorder. Solidification times in castings and metallic moulds were determined from the cooling and heating curves at various locations in casting and mould. The results showed that the solidification time obtained by experimental study compares favourably well with that determined by the analysis made through simulation modelling.