Simulation of Defect Formation in Castings

Direct, physics-based modeling of casting defects (e.g., porosity, hot tears and inclusions) has received increased research attention during the last decade. Users of casting simulation are no longer satisfied with solutions of the heat flow problem and the use of simple criterion functions to indicate the likelihood of a defect occurring. Instead, sophisticated models are being developed to directly simulate the physical processes associated with defect formation. The ultimate goal of these models is to provide quantitatively accurate predictions of the location, size and shape of casting defects. These predictions are then used in mechanical analyses to evaluate the effect of the defects on the performance of a casting in service. An overview is provided of recent progress in the modeling of defect formation in casting processes. Examples are provided for steel, aluminium, and magnesium castings.