MICRO-MACRO MODELLING OF SOLIDIFICATION WITH EXPERIMENTAL VALIDATION IN SELECTED EUTECTIC BINARY

In the pursuit of increased knowledge during component manufacturing, experimental and numerical studies of solidification phenomena have continued to complement each other. The dynamism of engineering designs, combined with the demand for lighter and better materials, have kept the modelling of casting systems progressing in recent decades. The current research includes simulations of solidification conditions for several aluminum-based eutectic binary alloys, as well as experimental confirmation. Using metallic, sand, quartz, and Plaster of Paris (POP) moulds, the effect of mould material on the solidification of Al-4.5 percent Cu was investigated. The micro-macro model previously developed by the current authors was used to simulate the eutectic alloys. In a static casting process, the effect of mould size and the transient change of structure during solidification were successfully replicated. The experimental findings revealed that, while the cooling curves for the various mould materials are essentially similar, they react differently to the presence of liquid metal, resulting in dramatically varying rates of latent heat evolution. Simulations of cooling curves for four eutectic alloys consolidated in a sand mould revealed that Al-4.5 percent Cu and Al-3.0 percent Si had the fastest transformations, while Al-6.0 percent Mg and Al-3.0 percent Zn have the slowest. Because smaller moulds attain steady-state and homogenise faster than larger ones, mould size has a substantial impact on thermal distribution during solidification. The nucleation period is quite short in comparison to the entire solidification time for all of the alloys studied. Transient evolution of volumetric grain density and grain radius differed greatly, according to the findings.

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