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Russian Journal of Non-Ferrous Metals

, Volume 59, Issue 6, pp 617–623 | Cite as

Prediction of Misruns in ML5 (AZ91) Alloy Casting and Alloy Fluidity Using Numerical Simulation

  • A. V. PetrovaEmail author
  • V. E. BazhenovEmail author
  • A. V. KoltyginEmail author
FOUNDRY
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Abstract

Predicting the misrun formation in thin-walled castings of magnesium alloys is a critical task for foundry. The computer simulation of casting processes can be used to solve this problem. Adequate results of simulation can be attained in the presence of the correct thermal properties of the alloy and a mold in a wide temperature range, interface heat-transfer coefficient between the casting and a mold, and the critical solid fraction (at which the melt flow in a mold is stopped). In this work, the interface heat-transfer coefficient between the ML5 (AZ91) magnesium alloy and a no-bake sand mold is found by comparing simulation spiral test lengths with experimental spiral test lengths under the same pouring conditions. Its values above the liquidus temperature are hL = 1500 W/(m2 K) at pouring temperatures of 670 and 740°C and hL = 1800 W/(m2 K) at 810°C. Below the solidus temperature, hS = 600 W/(m2 K). The critical solid fraction for the ML5 (AZ91) magnesium alloy was also determined for no-bake mold casting (with a cooling rate of ~2 K/s)—its value was 0.1–0.15. The critical solid fraction is refined by comparing the position of misruns by the results of simulation and in an actual “Protective cap” ML5 (AZ91) alloy casting poured into the no-bake mold. Castings are poured at temperatures of 630 and 670°C, and the critical solid fraction is 0.1 in both cases.

Keywords:

fluidity simulation magnesium alloy coherency point spiral fluidity test ProCast misruns 

Notes

ACKNOWLEDGMENTS

This study was supported by the Ministry of Education and Science of the Russian Federation, contract no. 03.G25.31.0274 dated May 27, 2017, and a Grant of the President of the Russian Federation to young scientists and postgraduates who are carrying out scientific investigations and developments in the priority directions of the Russian Federation’s economy modernization (2016–2018 contest).

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Copyright information

© Allerton Press, Inc. 2018

Authors and Affiliations

  1. 1.National University of Science and Technology “MISiS”MoscowRussia

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