Numerical simulation of mold filling process for high chromium cast iron matrix composite reinforced by ZTA ceramic particles

The mold filling process of high chromium cast iron matrix composites reinforced by zirconia toughened alumina (ZTA) ceramic particles (referred as HCCI/ZTAP composites hereinafter) by infiltration casting were simulated using finite element analysis software in this paper. Volume of fluid (VOF) method and porous medium model were used to describe the flow phenomenon during infiltration process. Multiphase flow and heat transfer equations were solved by finite element method. The comparison between the experimental observations and simulation results indicates that the formulated model and method could provide a solution with acceptable accuracy, thus a promising tool to optimize the processing parameters. After trial calculations, the optimal parameters and pouring system were determined eventually. A complete casting without any defects was prepared at the pouring temperature of 1843 K and pouring velocity of 0.2 m/s by top filling in an enclosed gating system.