Simulation of mold filling and solidification on gravity casting of Al-Si alloy (A357)

Abstract：In order to understand the solidification and feeding process of the sample, the temperature at specific positions was measured by multi-channel data acquisition system.By using Olympus metallurgical microscope, the macrostructure of the casting was observed and freezing mechanism was analyzed.The mold filling and solidification processes of the Al-alloy sample were studied by using the commercialized simulation software Z-Cast.Compared with simalated and practical pouring test results, it is indicated that when preheat temperature of mold is low, the pouring temperature should be higher to ensure completely filling of mold.As a result the solidification of sample could be feeding effectively, and the shrinkage on the upper end of sample could be eliminated.It is shown that the casting simulation software Z-CAST can be used to simulate the filling and solidification process of gravity cast Al alloy and can provide exact flow fields and temperature fields thus can predict cast defects and their positions.

Keyword：Al-Si alloy;temperature;solidification process;simulation;