Computation of solidification of Al-4.5% Cu alloy casting cast in CO2-sand mould

Solidification of molten metals during various casting methods poses many practical problems associated with phase transformation and heat transfer processes. Evaluation of solidification time is one of the very important parameters used for assessing the properties of the material. In the present study, an experimental investigation was carried out to measure the solidification time in a cylindrical hollow casting cast in CO2-sand moulds and the same has been compared with computed results obtained using an implicit alternating direction (IAD) method, including the treatment of interfacial nodes between metal and mould, and boundary nodes at the mould surface. Aluminium-4.5% Cu alloy was used. Computed cooling curves at various locations and temperature distributions in core-metal-mould were presented. The results show that the solidification time obtained in the experimental study compares well with that predicted by the analysis made through IAD modelling. A successful comparison with reported experimental results shows that the technique is appropriate for simulation of the solidification process of aluminium castings. [PUBLICATION ABSTRACT]