Influence of oxide film defects generated in filling on the mechanical strength of aluminium alloy castings

X. Dai, X. Yang, J. Campbell, J. Wood

Research output: Contribution to journalArticle

52 Citations (Scopus)

Abstract

The influence of oxide film defects generated from the filling process on the mechanical strength of aluminium alloy castings has been investigated. Using numerical simulation and experimental validation, the investigation aims to reveal the relationships among the liquid aluminium flow behaviour in the filling, the likely oxide film defect distribution caused by surface turbulence and the final mechanical strength of the castings. CFD modelling was used to investigate the liquid metal flow behaviour and the likely oxide film defect distribution in the filling at different ingate velocities. In particular, a numerical algorithm - Oxide Film Entrainment Tracking (OFET, 2-D) has been proposed and developed for predicting such oxide film defect distribution in the liquid aluminium throughout the filling. Also, light microscopic and SEM techniques were used to identify the microstructures of oxide film casting defects. The Weibull statistics method was employed to quantify the effects of oxide film distributions on the mechanical strength and reliability of the acquired aluminium alloy castings for different runner systems. It was found from the numerical simulations that the ingate velocities acquired using different runner systems have significant influence on the distribution of oxide film defects generated by surface turbulence in the filling process, which results in the disparities of the final mechanical strength of the castings. The results of the mechanical property test and the SEM micro-structural analysis of the castings are consistent with the numerical simulations.
LanguageEnglish
Pages505-513
Number of pages8
JournalMaterials Science and Technology
Volume20
Issue number4
DOIs
Publication statusPublished - Apr 2004

Fingerprint

aluminum alloys
Oxide films
Strength of materials
oxide films
Aluminum alloys
Defects
defects
Aluminum
Computer simulation
Turbulence
turbulence
aluminum
Organic field effect transistors
Scanning electron microscopy
scanning electron microscopy
Castings
simulation
Liquids
entrainment
liquids

Keywords

  • alluminium alloys
  • casting
  • oxide films
  • film defects

Cite this

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abstract = "The influence of oxide film defects generated from the filling process on the mechanical strength of aluminium alloy castings has been investigated. Using numerical simulation and experimental validation, the investigation aims to reveal the relationships among the liquid aluminium flow behaviour in the filling, the likely oxide film defect distribution caused by surface turbulence and the final mechanical strength of the castings. CFD modelling was used to investigate the liquid metal flow behaviour and the likely oxide film defect distribution in the filling at different ingate velocities. In particular, a numerical algorithm - Oxide Film Entrainment Tracking (OFET, 2-D) has been proposed and developed for predicting such oxide film defect distribution in the liquid aluminium throughout the filling. Also, light microscopic and SEM techniques were used to identify the microstructures of oxide film casting defects. The Weibull statistics method was employed to quantify the effects of oxide film distributions on the mechanical strength and reliability of the acquired aluminium alloy castings for different runner systems. It was found from the numerical simulations that the ingate velocities acquired using different runner systems have significant influence on the distribution of oxide film defects generated by surface turbulence in the filling process, which results in the disparities of the final mechanical strength of the castings. The results of the mechanical property test and the SEM micro-structural analysis of the castings are consistent with the numerical simulations.",
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Influence of oxide film defects generated in filling on the mechanical strength of aluminium alloy castings. / Dai, X.; Yang, X.; Campbell, J.; Wood, J.

In: Materials Science and Technology, Vol. 20, No. 4, 04.2004, p. 505-513.

Research output: Contribution to journalArticle

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AB - The influence of oxide film defects generated from the filling process on the mechanical strength of aluminium alloy castings has been investigated. Using numerical simulation and experimental validation, the investigation aims to reveal the relationships among the liquid aluminium flow behaviour in the filling, the likely oxide film defect distribution caused by surface turbulence and the final mechanical strength of the castings. CFD modelling was used to investigate the liquid metal flow behaviour and the likely oxide film defect distribution in the filling at different ingate velocities. In particular, a numerical algorithm - Oxide Film Entrainment Tracking (OFET, 2-D) has been proposed and developed for predicting such oxide film defect distribution in the liquid aluminium throughout the filling. Also, light microscopic and SEM techniques were used to identify the microstructures of oxide film casting defects. The Weibull statistics method was employed to quantify the effects of oxide film distributions on the mechanical strength and reliability of the acquired aluminium alloy castings for different runner systems. It was found from the numerical simulations that the ingate velocities acquired using different runner systems have significant influence on the distribution of oxide film defects generated by surface turbulence in the filling process, which results in the disparities of the final mechanical strength of the castings. The results of the mechanical property test and the SEM micro-structural analysis of the castings are consistent with the numerical simulations.

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