Modelling of defects in aluminium cast products

Over the last 4 decades, remarkable progress has been made in the modelling of casting processes. The development of casting models is well reflected in the proceedings of the 15 Modelling of Casting, Welding and Advanced Solidification Processes (MCWASP) conferences that have been held since 1980. Computer simulations have enabled a better understanding of the physical phenomena involved during solidification. Modelling gives the opportunity to uncouple the physical processes. Furthermore, quantities that are difficult or impossible to measure experimentally can be calculated using computer simulations e.g. flow patterns and recalescence. However, when it comes to accurately predicting casting performance and in particular, the occurrence of defects like cracks, segregation and porosity there is certainly some way to go. In this paper, the current understanding of the main mechanisms of defect formation during shape and DC casting processes will be reviewed and requirements will be discussed to give a direction to making casting models more predictive and quantitative

Linear Contraction Behavior of Low-Carbon, Low-Alloy Steels During and After Solidification Using Real-Time Measurements

A technique for measuring the linear contraction during and after solidification of low-alloy steel was developed and used for examination of two commercial low-carbon and low-alloy steel grades. The effects of several experimental parameters on the contraction were studied. The solidification contraction behavior was described using the concept of rigidity in a solidifying alloy, evolution of the solid fraction, and the microstructure development during solidification. A correlation between the linear contraction properties in the solidification range and the hot crack susceptibility was proposed and used for the estimation of hot cracking susceptibility for two studied alloys and verified with the real casting practice. The technique allows estimation of the contraction coefficient of commercial steels in a wide range of temperatures and could be helpful for computer simulation and process optimization during continuous casting. © 2013 The Minerals, Metals & Materials Society and ASM International

Formation of hot tear under controlled solidification conditions

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window-compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.This research was carried out within the Materials innovation institute (www.m2i.nl) research framework, project no. M42.5.09340

Cross-sectional classification of aluminium beams subjected to fire

Fire design for aluminium alloy beams is performed using the same system of cross-sectional slenderness classes as is employed at room temperature. Identical width-over-thickness ratio limits are used to define the boundaries between the classes. These limits are known (and demonstrated) to be conservative, but may in fact be over-conservative. Especially for tempered alloys, the geometric limits may be relaxed considerably, allowing cross-sections to be upgraded in class for fire design calculations