Research Papers

MAGMASOFT Simulation of Sand Casting Process With EV31A Magnesium Alloy

[+] Author and Article Information
Robert Jarosz

ZM “WSK Rzeszow,”
Hetmańska STR. 120,
Rzeszów 35-078, Poland
e-mail: jarosz.robert@zmwskrz.com

Andrzej Kiełbus

Department of Materials Science and Metallurgy,
Silesian University of Technology,
Krasińskiego STR. 8,
Katowice 40-019, Poland
e-mail: andrzej.kielbus@polsl.pl

Bartłomiej Dybowski

Department of Materials Science and Metallurgy,
Silesian University of Technology,
Krasińskiego STR. 8,
Katowice 40-019, Poland
e-mail: bartłomiej.dybowski@polsl.pl

1Corresponding author.

Contributed by the Materials Division of ASME for publication in the JOURNAL OF ENGINEERING MATERIALS AND TECHNOLOGY. Manuscript received July 22, 2016; final manuscript received January 18, 2018; published online February 8, 2018. Assoc. Editor: Vadim V. Silberschmidt.

J. Eng. Mater. Technol 140(3), 031001 (Feb 08, 2018) (9 pages) Paper No: MATS-16-1206; doi: 10.1115/1.4039108 History: Received July 22, 2016; Revised January 18, 2018

Magnesium alloys with rare earth (RE) elements addition, modified with zirconium are used for cast, light-weight solutions for components applied at temperature up to 250–300 °C. Computational methods are often used by the foundries to decrease the cost of a new product start-up. The commercially available magmasoft software is widely used to simulate a casting process. Nevertheless, its database does not contain complete data for modern alloys. We present the results of our investigations on the thermo-physical properties of a EV31A magnesium alloy and the simulation of a sand casting process with applied data. We compared the simulation and technological trials, recognized problems occurring during the simulation, and applied corrections. Our final simulations gave acceptable results. The differences between the technological tests and the simulation were caused by factors that are difficult to model in the simulation, such as the presence of nonmetallic inclusions and the degree of modification of the liquid alloy.

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Fig. 1

Fluidity helix scheme

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Fig. 2

Designed models: (a) sample with the gating system, (b) bottom part of the mold, and (c) top part of the mold

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Fig. 3

Intermetallic phases formed in the eutectic reaction in the EV31A alloy

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Fig. 4

Energy dispersive spectroscopy (EDS) spectrum for the phase pointed in Fig. 3(b)

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Fig. 5

Globular phase rich in Zr (a) and EDS spectrum (b) for that particle

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Fig. 6

Globular phase rich in Zr (a) and EDS spectrum (b) for that particle

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Fig. 7

EV31A alloy (a) density and (b) specific heat as a function of temperature

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Fig. 8

EV31A alloy (a) thermal diffusivity and (b) conductivity as a function of temperature

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Fig. 9

DSC curves recovered during heating of the EV31A alloy

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Fig. 10

DSC curves recovered during cooling of the EV31A alloy

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Fig. 11

Density as a function of temperature for typical RZ5 magnesium alloy present in the magmasoft database

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Fig. 12

Introduced density as a function of temperature for EV31A magnesium alloy: (a) with a constant value after 1000 °C and (b) with interpolated data up to 2000 °C

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Fig. 13

Simulation of flow of the liquid alloy in the mold cavity, cast at 755 °C: (a) 25% of cavity volume filled and (b) 70% of cavity volume filled

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Fig. 14

Simulation of solidification of the liquid alloy in the mold cavity, cast at 755 °C: (a) 25% of solid phase and (b) 100% of solid phase

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Fig. 15

Temperature distribution in the furane mold, alloy cast at 755 °C: (a) after the pouring process and (b) after full solidification of the specimen

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Fig. 16

Different pouring rates: (a) too high and (b) a satisfactory rate

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Fig. 17

Difficulties in simulation process: (a) a long time is needed for calculations and (b) completely filled mold cavity

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Fig. 18

Oxides present in the EV31A alloy structure: (a) bulky inclusion and microshrinkage and (b) thin film inclusion




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