Skip to main content Accessibility help
×
Home

Prediction of the contact time through modeling of heat transfer and fluid flow in compound casting process of Al/Mg light metals

  • Morteza Morakabian Esfahani (a1), Esmaeil Hajjari (a1), Ali Farzadi (a2) and Seyed Reza Alavi Zaree (a1)

Abstract

In this study, the time that molten magnesium is in contact with the aluminum insert before solidification was predicted by solving the conservation equations of mass, momentum, and energy during compound casting of dissimilar Al/Mg couples. For this purpose, a three-dimensional transient model and FLOW-3D software were utilized and distributions of temperature and velocity vectors in the fluid over time were obtained. Then, the contact time at the bottom, middle, and top of aluminum insert in its interface with the magnesium melt was calculated. The results of simulation show that the contact time decreases from about 1.7 s at bottom to 1.6 s at middle and 0.8 s at top of the interface, respectively. This is consistent with the experimental metallographic observations which indicate a decrease in the thickness of formed intermetallic compounds from bottom to middle and top of the Al/Mg interface.

Copyright

Corresponding author

a) Address all correspondence to this author. e-mail: e.hajjari@scu.ac.ir

Footnotes

Hide All

Contributing Editor: Jürgen Eckert

Footnotes

References

Hide All
1. Papis, K.J.M., Hallstedt, B., Loffler, J.F., and Uggowitzer, P.J.: Interface formation in aluminium–aluminium compound casting. Acta Mater. 56, 3036 (2008).
2. Horikawa, N., Ito, T., Noguchi, T., and Nakamura, T.: Size effect in cast-in insertion process. Int. J. Cast Met. Res. 16, 365 (2003).
3. Ho, J.S., Lin, C.B., and Liu, C.H.: Effect of continuous cooling heat treatment on interface characteristics of S45C/copper compound casting. J. Mater. Sci. 39, 2473 (2004).
4. Choe, K.H., Park, K.S., Kang, B.H., Cho, G.S., Kim, K.Y., Lee, K.W., Kim, M.H., Ikenaga, A., and Koroyasu, S.: Study of the interface between steel insert and aluminum casting in EPC. J. Mater. Sci. Technol. 24, 60 (2008).
5. Papis, K.J.M., Loffler, J.F., and Uggowitzer, P.J.: Interface formation between liquid and solid Mg alloys—An approach to continuously metallurgic joining of magnesium parts. Mater. Sci. Eng., A 527, 2274 (2010).
6. Divandari, M. and Vahid Golpayegani, A.R.: Study of Al/Cu rich phases formed in A356 alloy by inserting Cu wire in pattern in LFC process. Mater. Des. 30, 3279 (2009).
7. Xiong, B., Cai, C., and Lu, B.: Effect of volume ratio of liquid to solid on the interfacial microstructure and mechanical properties of high chromium cast iron and medium carbon steel bimetal. J. Alloys Compd. 509, 6700 (2011).
8. Dezellus, O., Milani, L., Bosselet, F., Sacerdote-Peronnet, M., Roubyb, D., and Viala, J.C.: Mechanical testing of titanium/aluminium–silicon interfaces by push-out. J. Mater. Sci. 43, 1749 (2008).
9. Volder, J.P.: An overview of a number of casting processes. Aluminum 4, 11 (1993).
10. Emami, S.M., Divandari, M., Arabi, H., and Hajjari, E.: Effect of melt-to-solid insert volume ratio on Mg/Al dissimilar metals bonding. J. Mater. Eng. Perform. 22, 123 (2013).
11. Noguchi, T., Horikawa, N., Nagate, H., Nakamura, T., and Sato, K.: Application of flow and solidification simulation in cast-in insertion processing. Int. J. Cast Met. Res. 18, 214 (2005).
12. Guangchen, X., Alan, A.L., Yiqing, C., and Anil, K.S.: Interfacial phenomena in magnesium/aluminum bi-metallic castings. Mater. Sci. Eng., A 595, 154 (2014).
13. Papis, K.J.M., Loeffler, J.F., and Uggowitzwr, P.J.: Light metal compound casting. Sci. China, Ser. E: Technol. Sci. 52, 46 (2009).
14. Hajjari, E., Divandari, M., Razavi, S.H., Emami, S.M., Homma, T., and Kamado, S.: Dissimilar joining of Al/Mg light metals by compound casting process. J. Mater. Sci. 46, 6491 (2011).
15. Hajjari, E., Divandari, M., Razavi, S.H., Homma, T., and Kamado, S.: Microstructure characteristics and mechanical properties of Al 413/Mg joint in compound casting process. Metall. Mater. Trans. A 43, 4667 (2012).
16. Cho, M.H., Lim, Y.C., and Farson, D.F.: Simulation of weld pool dynamics in the stationary pulsed gas metal arc welding process and final weld shape. Weld. J. 85, 271 (2006).
17. Cao, Z., Yang, Z., and Chen, X.L.: Three-dimensional simulation of transient GMA weld pool with free surface. Weld. J. 85, 169 (2004).
18. Flow-3D Database, Ver.10.0, www.flow3d.com, December 2016.
19. Farzadi, A., Serajzadeh, S., and Kokabi, A.H.: Investigation of weld pool in aluminium alloys: Geometry and solidification microstructure. Int. J. Therm. Sci. 49, 809 (2010).
20. Hajjari, E., Divandari, M., Razavi, S.H., Emami, S.M., and Kamado, S.: Estimation of the transient interfacial heat flux between substrate/melt at the initiation of magnesium solidification on aluminum substrates using the lumped capacitance method. Appl. Surf. Sci. 257, 5077 (2011).

Keywords

Prediction of the contact time through modeling of heat transfer and fluid flow in compound casting process of Al/Mg light metals

  • Morteza Morakabian Esfahani (a1), Esmaeil Hajjari (a1), Ali Farzadi (a2) and Seyed Reza Alavi Zaree (a1)

Metrics

Full text views

Total number of HTML views: 0
Total number of PDF views: 0 *
Loading metrics...

Abstract views

Total abstract views: 0 *
Loading metrics...

* Views captured on Cambridge Core between <date>. This data will be updated every 24 hours.

Usage data cannot currently be displayed