Abstract
Controlling and eliminating defects, such as macroporosity, in castings is a continuing challenge that manufacturers must continually address. Since the encapsulation of liquid regions by a solid shell and subsequent formation of macroporosity cannot be detected during casting, the die temperature, which is routinely measured, has been used as an indirect indicator of this defect. A finite element model has been developed to predict the evolution of temperature as well as the volume of encapsulated liquid in a casting with a high propensity to form macroporosity. The boundary conditions in the model were iteratively adjusted until the temperature predictions matched the experimental data for a variety of operational conditions. A model based methodology has been developed to analyse the correlation between the die temperature and the encapsulated liquid volume. This methodology is employed to assess the suitability of different in-cycle die temperatures for use as indicators of macroporosity formation, and to help determine the optimal location to monitor temperature for the purpose of minimising macroporosity.
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