Numerical Simulation of Porosity for Al Based Alloys

The final integrity of a casting is greatly influenced by the presence of porosity. Progressive way to predict presence of porosity is the use of modern computer simulation programs. The main aim of performed experiments is to verify possibilities of this promising method of porosity prediction. A calculation of advanced porosity prediction was performed for an aluminium alloys by advanced porosity module included in ProCAST software. This calculation takes into account all basic phenomena, which are at the origin of micro and macro porosity. For experiment purposes was used mold with specific shape - Sanduhrprobe. Materials used in experiments were not loaded from software database, because results could be distorted by deviations from particular material we used. To achieve precise results, we used thermal analysis to get accurate data about used alloys. Important solidification events, which affects porosity formation, such as recoalescence and nucleation undercooling temperature, coherence point and rigidity point have been determined from cooling curves and its first derivate. These data were then included to the database of simulation software and used in simulation process.