Numerical Simulation and Defect Identification in the Casting of Co-Cr Alloy

The development of biomaterials, particularly metallic ones, is one of the focuses of the scientific community, mainly due to an increase of average life expectancy and an improvement of the casted materials combined with better mechanical properties and defect-free products. The use of cobalt alloys in applications, such as knee, hip, and dental prostheses, is the result of their good ability to maintain mechanical properties and biocompatibility over long periods of use. Numerical methods are becoming more important, as they help product improvement in a faster and economic way. This work focuses on the development of a numerical model in ProCAST®, comparing the shrinkage porosity and cooling curves with real castings. When correlating simulation results with available experimental data, it is possible to understand that the formulated model demonstrates an acceptable solution in terms of precision (shrinkage porosity and cooling curve). The alloy’s thermal properties and heat conditions were iteratively changed until the developed numerical model turned out a viable tool for this specific alloy when used in the investment casting process.