Simulation of casting solidification

1.4 Literature Review

Since last three decades using of programming entered to casting
filed (design and analyses). The available of high speed processors helped
in developing a new programs and packages used in this purpose. Watts
and Veerman [42], developed a program to locate the riser and they find
there is an increasing in casting yield. Hinene [43], studied a heat transfer
within a riser, he noted that with the aide of computer there is a profit in
production and reducing in energy. Niyama et al [22], made a mapping of
the calculated heat gradient at the time of solidification of large steel
casting, and they found that it was a powerful tool for predicating
shrinkage porosities, particularly those occurring along the centerline of
the casting. They have found that the porosities were formed in those
areas where the G at the time of solidification was to be below 2-3 c/cm.
Imafuka and Chijiwa [44, 45], using a 2-D finite element analysis,
develop a model to predict the shape of gross shrinkage cavities and the
extent to microporosity surrounding them. They assumed that interdritic
flow would cease at fraction solid (fs) = 0.67. Any liquid trapped by a
mushy zone above this value will result in the formation of secondary
cavity. Isaac [46], used finite difference method (2D) to simulate heat
transfer through pure aluminum castings in metal mold. Ashton et al [47],
used computer program and 3D modeling to made thermal analyses for
casting system to provide a production and decreasing operation time.
Nagasaka et. al. [48], used a similar method but with a solid fraction
gradient as key parameter. Rappaz [49], made a comparison between
analytical methods used to analyze casting system (finite element, finite
difference, volume element, and boundary element), and found that finite
element method and finite difference method are more common in used.
Charach and Zarmy [50], proposed an analytical solution for planar

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solidification in a finite thickness slab by transforming the problem to one
without the density change. Sigworth and wang [51], derive a model for
centerline shrinkage based on geometric arguments. They argue that
pinching - off of liquid areas along the plate centerline due to uneven
solidification causes the shrinkage in plates. The presence of gradients in
the feeding direction serves to open up a channel by effectively a taper to
the inner liquid channel. Huang and Akay [52], studied a heat transfer
phenomena at cast-mold interface. Trovant and Argyropoulos [53],
proposed an algorithm to account for shrinkage and consequently
determine the shrinkage profile resulting from phase and density change.
Campell and Wright [54], improved using of cooling fins by simulation
of solidification and calculate solidification time. Qasssim Daws [55],
developed a program steel castings solidification and derived an equation
to calculate a less length of runner. Huang et al [56], studied a heat
transfer and casting solidification in car engine production using
(Power cast) program. Celentano [57], presented a macroshrinkage
prediction criteria for thermomechanical analysis of shaped casting, the
internal shrinkage developed in the liquid phase is predicted by means of
the void volumetric fraction calculated from the volumetric strains
according to the restriction of non-positive liquid pressure. Moreover, the
internal and external shrinkage (surface) effects have been predicted.
Beech et. al. [58], present a computer modeling method for
macroshrinkage cavity prediction. The method is based on the solution of
the heat flow equations for the casting and the mould. The shrinkage
cavity volume and location is then predicted by evaluating the volume
change of the solidification contraction in each isolated liquid region of
the casting at any given time. A study by Li et. al. [59], has been carried
out of the porosity exhibited in shaped castings made in short, medium,
and longe freezing range aluminum alloys. The castings were provided

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either with no feeds, or with inadequate feeders. It was observed that the
volume deficit on freezing tended to be partially internal as porosity, and
partially external in the form of surface depressions. The progression
from short to long freezing range was seen in general to decrease the
internal porosity, and increasing the external sinking. Also, it was found
that pouring temperature within the limited range investigated had little
effect on the amount of porosity. Orientation also had little effect on the
total, but greatly affected the position and form of the porosity. In most
cases the external sinks were to be found on the upper parts of the
casting. Bride et. al. [60], presented a model that accounts for shrinkage
during the directional solidification or dendritic binary alloy under the
assumption that the densities of liquid and solid phase are different but
constant. Yapping [61], simulated a continuous casting for large
aluminum castings by finite element method to locate hot spot and
analyze thermal stresses. Bounds et. al. [62], proposed a model for macro
defect predictions based on the coupling of the free-surface flow, heat
transfer, and solidification. Pequet et. al. [63], develop a microporosity
model based on the solution of Darcy's equation and microsegregation of
gas, for arbitrary 2D and 3D geometry and coupled for the first time with
macroporosity and pipe-shrinkage predictions. In order to accurately
calculate the pressure drop within the mushy zone, a dynamic refinement
technique has been implemented. Fard et. al. [64], develop a numerical
method, to simulate the solidification shrinkage of the solidifying liquid.