Abstract
Simulations are performed for the squeeze casting of AM60 and AZ91 automotive control arms. Advanced feeding flow and stress models are used within commercial casting simulation software to predict shrinkage porosity and hot tears. The simulations are validated through comparisons with observations made on experimental castings. Generally good agreement is obtained between the measured and predicted defect locations and extents. Design and process changes are introduced to mitigate the shrinkage and hot tear problems in these castings. The comparisons in the present study establish considerable confidence in the ability of casting simulation to predict shrinkage and hot tears in squeeze casting of magnesium alloys.
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
Preview
Unable to display preview. Download preview PDF.
References
K.D. Carlson, Z. Lin, R.A. Hardin, C. Beckermann, G. Mazurkevich, and M.C. Schneider, “Modeling of Porosity Formation and Feeding Flow in Steel Casting,” Modeling of Casting, Welding and Advanced Solidification Processes — X, ed. D.M. Stefanescu et al., (Warrendale, PA: TMS, 2003), pp. 295–302.
K.D. Carlson, Z. Lin and C. Beckermann, “Modeling the Effect of Finite-Rate Hydrogen Diffusion on Porosity Formation in Aluminum Alloys,” Metall. Mater. Trans. B, 36B (2007), pp. 541–555.
M.G. Pokorny, C.A. Monroe, C. Beckermann, L. Bichler, and C. Ravindran, “Prediction of Hot Tear Formation in a Mg Alloy Permanent Mold Casting,” Int. J. Metalcasting, 2 (2008), pp. 41–53.
C.A. Monroe, C. Beckermann, and J. Klinkhammer, “Simulation of Deformation and Hot Tears Using a Visco-Plastic Model with Damage,” Modeling of Casting, Welding, and Advanced Solidification Processes — XII, ed. S.L. Cockcroft and D.M. Maijer (Warrendale, PA: TMS, 2009) pp. 313–320.
M.G. Pokorny, C.A. Monroe, C. Beckermann, Z. Zhen, and N. Hort, “Simulation of Stresses During Casting of Binary Magnesium-Aluminum Alloys,” Metall. Mater. Trans. A, (in press, 2010).
JMatPro v.4.0, Sente Software Ltd., Surrey Technology Centre, Surrey GU2 7YG, United Kingdom.
MAGMAsoft v4.5, Magma GmbH, Aachen, Germany.
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2011 TMS (The Minerals, Metals & Materials Society)
About this chapter
Cite this chapter
Carlson, K.D., Beckermann, C., Jekl, J., Berkmortel, R. (2011). Simulation of Porosity and Hot Tears in a Squeeze Cast Magnesium Control Arm. In: Sillekens, W.H., Agnew, S.R., Neelameggham, N.R., Mathaudhu, S.N. (eds) Magnesium Technology 2011. Springer, Cham. https://doi.org/10.1007/978-3-319-48223-1_19
Download citation
DOI: https://doi.org/10.1007/978-3-319-48223-1_19
Publisher Name: Springer, Cham
Print ISBN: 978-3-319-48568-3
Online ISBN: 978-3-319-48223-1
eBook Packages: Chemistry and Materials ScienceChemistry and Material Science (R0)