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Project
Multiscale Modeling of Metal Casting



Description:

To develop models describing the importance and role of oxide bi-films in initiating porosity formation and hence postulate potential methods of minimizing this effect.

Cast Components


Scientific Merit
• To minimizing the effects of oxide film in melt.
• To develop models describing the effects of surface integrity, including residual stress patterns in finish machining and heat treatment processes.

Background
• Dispersed pores are detrimental to fatigue life and impact resistance
• Porosity formation associates with the bi-films (folded oxide films)
• Degradation of surface integrity from the surface residual stress formation
during heat treatment and final machining

Aluminum Die-Cast Engine Block


Crack Initiation Study


Die-Casting to Experimental Study


Status
• Collecting data on melting and casting variables during die-cast injection process.
• Simulating die-casting process using solidification simulation software to predict macro-porosity potential.
• Reduce number of component rejects by utilizing quality control technique such as the Taguchi Method

Future Work
• Develop modeling capability that captures plastic anisotropy, damage, and grain growth that is validated experimentally and verified numerically.