Modeling of interdendritic porosity defects in an integrated computational materials engineering approach for metal casting
Abstract Modelling and simulation of multiphysical phenomena need to be considered in the design and optimisation of mechanical properties of cast components in order to accelerate the introduction of new cast alloys. The data on casting defects, including microstructure features, are crucial for evaluating the final performance related properties of the component. In this paper, the required models for the prediction of interdendritic casting defects, such as microporosity and hot tears, are reviewed. The data on calculated solidification shrinkage are presented and its effects on microporosity levels discussed. Numerical simulation results for microporosity are presented for A356, 356 and 319 aluminium alloys using ProCAST(tm) software. The calculated pressure drop of the interdendritic liquid was observed to be quite significant and the regions of high pressure drop can be used as an indicator on the severity of interdendritic microporosity defects.