Thermo-Mechanical Phenomena in Aluminum Alloy Casting During Cooling – Experimental Simulation

Commonly available foundry simulation codes such as NovaFlow & Solid, Magma or ProCAST contain modules that allow to predict thermo-mechanical phenomena during the cooling of castings. However, due to the limited quantity and quality (certainty) of the values of mechanical parameters contained in databases, they are not readily used by the industry. The codes remain in the sphere of scientific considerations concerning mainly cast iron alloy castings. The article describes the problem of stress prediction in aluminum alloy castings. An experimental and virtual research methodology for the verification of residual (thermal) stress has been developed. As part of the methodology, a modified stress test has been developed, which uses a stress lattice. The location of the gating system has been modified, and to prevent the formation of shrinkage cavities, chills have been used. Moreover, in order to obtain higher rigidity of the structure, thin steel rods have been inserted before the pouring process. Such a solution has made it possible to conduct experimental simulation validation of the NovaFlow & Solid simulation code Stress module.