Application of Multiphase Modelling in Semi-Solid Die Casting: Blister Prediction

Abstract:

One-phase modelling is widely used as an optimization and design tool for semi-solid casting process. By this approach, semi-solid alloy is taken as a homogeneous fluid and flow behaviours are represented by using the rheological properties of the mixture. A single set of conservation equations is solved to simulate the mould filling, without considering the different motilities between the liquid and the solid phase. Therefore, defects due to phase segregation cannot be predicted and particle tracking cannot be carried out. This study is focused on multiphase (i.e. a liquid-particle-air system) modelling during the semi-solid filling process of a thin-walled component. By using this approach, the solid phase is treated as a power law fluid and the phase interactions among the phases are introduced for the semi-solid alloy system. Practical semi-solid die casting is carried out for verification of phase segregation. The final distribution of air is calculated and proved by practical blistering examination. The simulation results are verified to be accurate in a reasonable range, indicating an approach for modelling semi-solid filling including the formation (and avoidance) of blisters.

• Periodical: Solid State Phenomena (Volume 256)
• Pages: 139-145
• DOI: https://doi.org/10.4028/www.scientific.net/SSP.256.139
• Online since: September 2016
• Authors: Xiao Gang Hu, Qiang Zhu*, H.V. Atkinson, Min Luo, Fan Zhang, Wen Ying Qu
• Keywords: Flow Visualisation, Multiphase Model, Phase Segregation, Semisolid Alloy

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