Modeling defects in castings using a volume of fluid method

Abstract

Purpose

A single-domain multi-phase model is developed for macrosegregation and shrinkage pipe formation in castings, as functions of buoyancy- and shrinkage-induced flow. The paper aims to discuss these issues.

Design/methodology/approach

Using a volume of fluid (VOF) method, both the air/liquid and air/solid interfaces are tracked during shrinkage pipe formation. A set of mixture advection-diffusion equations are derived and solved for velocity, temperature, composition, and phase field evolution. The fluid mechanics of the model are verified using a transient ditch drainage problem.

Findings

Results showing the interaction of macrosegregation and pipe formation are presented for two alloys under faster and slower cooling conditions.

Originality/value

This model provides a comprehensive tool to investigate relationships between the developing composition distribution and shrinkage pipe formation.

Citation

Zhang, S., Yanke, J., R. Johnson, D. and J.M. Krane, M. (2014), "Modeling defects in castings using a volume of fluid method", International Journal of Numerical Methods for Heat & Fluid Flow, Vol. 24 No. 2, pp. 468-482. https://doi.org/10.1108/HFF-08-2012-0185