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Journal of Materials Processing Technology 240 (2017) 249254

Contents lists available at ScienceDirect

Journal of Materials Processing Technology


journal homepage: www.elsevier.com/locate/jmatprotec

Optimizing gate location to reduce metal wastage: CoCrW alloy


lling simulation
Lintao Zhang a, , Fawzi Belblidia a , Helen M. Davies a , Nicholas P. Lavery a ,
Stephen G.R. Brown a , Dyfyr Davies b
a
Advanced Sustainable Manufacturing Technologies (ASTUTE2020) Operation, College of Engineering, Swansea University, Bay Campus, Fabian Way,
Swansea SA1 8EN, UK
b
Weartech International Ltd., Moor Road, Baglan Industrial Estate, Port Talbot SA12 7BJ, UK

a r t i c l e i n f o a b s t r a c t

Article history: This research aimed at reveal the reasons for the extra CoCrW alloy wastage in the risers in sand casting.
Received 16 June 2016 The alloy lling behaviour in both the original and modied moulds was investigated numerically. The
Received in revised form alloyair interface was captured by using volume of fraction method. For the original mould, an unlled
27 September 2016
volume in the vicinity of the runner bar top was apparent and it was relled by a back ow, originated
Accepted 30 September 2016
from the risers in the late stage of lling. The back ow behaviour required a higher level of the liquid
Available online 4 October 2016
alloy in the risers, which resulted in excessive wastage, and it was essential to form the required shape
of the cast. For the modied mould, the unlled volume was eliminated and the cast part shaping time
Keywords:
Sand casting
was reduced to around 10 s from 90 s. The alloy wastage in the risers was reduced by 11%.
Mould design 2016 Elsevier B.V. All rights reserved.
CoCrW alloy
Computational uid dynamics
Filling behaviour

1. Introduction the difculties that usually occurred when a step function was
transported by the pure advection. An adaptive grid method was
Sand casting process involves two main stages: the lling stage developed for the tetrahedral and hexahedral elements to simulate
and the solidication stage. Investigations on the lling stage are the mould lling for casting process (Kim et al., 2006). A sharp inter-
critical with regards to several aspects, for example, the congura- face solution algorithm (SOLA) particle level set method based on
tion optimization and the metal wastage analysis. the nite difference analysis was considered by Pang et al. (2010).
For the lling stage, the simulation can give a visualization of This straightforward method was successfully validated against the
the lling of the mould. This cannot be observed in the experiment benchmark simulation (Sirrell et al., 1995). To take into account
due to closed sand mould. Therefore, the numerical simulation the effect of the sand mould coating permeability, a mathemati-
is a powerful tool compared to the experimental research. Sev- cal model was developed based on the SOLA-volume of fraction
eral numerical schemes were introduced to capture the movement (SOLA-VOF) technique (Mirbagheri et al., 2003) and the results were
of interface between the air and the liquid alloy in the lling validated by the experiment of aluminium alloy within a transpar-
stage. The VOF-Leer scheme was adopted to simulate the three- ent mould. By coupling the new model and 3D-VOF techniques, the
dimensional lling behaviour of the liquid metals in the mould error for mould lling time was reduced to 16%. More importantly,
through two cases (Chan et al., 1991): slow lling to the large the investigation of the liquid metal lling behaviour were also used
scale sand-casting mould and a die-casting process. This technique to optimize the sand mould congurations, e.g. the gating systems
provided the realistic results that were validated by experiments. (Kermanpur et al., 2008; Sun et al., 2008; Du et al., 2015). Experi-
For a transient simulation, the pseudo-concentration formulation mentally, Assar (1999) showed the inuence of the lling mass ow
was also adopted (Ravindran and Lewis, 1998) to track the move- rate on the microstructure of Al4.5Cu ingots, especially that the
ment of the metal front on a xed mesh. This selection avoided coarser equiaxed grains and short columnar grains were obtained
as the lling rate was increased. The lling direction (top and bot-
tom) also had the effect on the tensile strength of the air cast 2L99
Corresponding author. AlSiMg alloy, 254-SMO super duplex stainless steel and vacuum
E-mail address: L.Zhang@swansea.ac.uk (L. Zhang). cast IN939 nickel based superalloys, respectively (Cox et al., 2000).

http://dx.doi.org/10.1016/j.jmatprotec.2016.09.027
0924-0136/ 2016 Elsevier B.V. All rights reserved.
250 L. Zhang et al. / Journal of Materials Processing Technology 240 (2017) 249254

alloy phase (L-phase) and the air phase (A-phase). The VoF method,
which has been well validated (Sun et al., 2012; Hargreaves et al.,
2014), is based on pressure-based solver, and allows to simulate
two or more immiscible uids by tracking the volume fraction of
each uid in the whole computing domain (ANSYS, 2013). In the
VoF model, the interface between L-phase and A-phase is captured
by solving Eq. (1) for the volume fraction of different phases. For
L-phase, Eq. (1) can be rewritten as:


2
t (L L ) + (L L uL ) = SL + (mAL mLA ), (3)
n=1
Fig. 1. CobaltChromeTungsten alloy cast. Different parts of the cast are named as
the pouring basin (1), the sprue (2), the choke (3), the turning part region (4), the where mAL (resp. mLA ) denotes the mass transfer from L (resp. A)
runner bar inlet (5), the front riser (6), the runner bar (7), the rear riser (8) and the phase to A (resp. L) phase. L denotes the volume of fraction of
runner bar end wall (9), respectively. phase L in the cell. Therefore, for a single cell:

The present research is based on an industrial problem, raised 0 empty of L-phase,
L = 0 L 1 mixture of L-phase and A-phase, (4)
by a local company. The main concerns of the company can be
summarized as follows: 1 full of L-phase.

In Eq. (3), SL is the source term of L-phase. In the present research,


1 the lling behaviour of CoCrW alloy in a specied (original)
the continuity equation was shared by L-phase and A-phase. The
mould conguration,
mass transfer between different phases was neglected and no
2 the solutions to reduce the extra alloy wastage in both risers,
source term was considered. Eq. (3) can be simplied as:
which was categorized as revert.
t (L L ) + (L L uL ) = 0. (5)
To address the above two concerns, the characterization of the
liquid CoCrW alloy lling behaviour within the specic mould For the A-phase, the volume of fraction can be obtained by the
conguration shall be conducted. The ultimate aim is to optimize following constrain:
the mould design to reduce the extra alloy wastage in risers. The L + A = 1. (6)
outline of the present paper is as follows. The conguration and
the numerical system are introduced in Section 2. In Section 3.1, The lling process is much shorter than the solidication process
the lling dynamics, in the region prior to the runner bar gate are so that an assumption could be considered: the ow behaviour is
assessed. In Section 3.2, the ow behaviour beyond the runner bar temperature independent (isothermal) during the lling stage. The
gate is analyzed, and nally the lling process for the modied SIMPLE scheme (Ferziger and Peric, 2002) was used to carry out the
mould conguration is discussed in Section 3.3. Main conclusions pressurevelocity coupling: a pressure was rst assumed and then
are summarized in Section 4. the velocity eld was calculated by solving Eq. (2). The determined
velocity was put in Eq. (5), until the continuity conservation was
achieved by modifying the pressure. For the spatial and the time
2. Conguration and numerical system
discretization schemes the second order upwind and the second
order implicit scheme were adopted.
2.1. Conguration
Due to the symmetric feature of the sand mould, only half of
the geometry was considered. The coordinate system was dened
Fig. 1 showed the cast sample which was originated from the
as follows: z axis and x axis were dened along the mainstream
sand mould. The various parts of the mould were labelled in Fig. 1.
directions of the liquid alloy in the sprue and the runner bar, respec-
The cast sample reects the inner conguration of the sand mould.
tively. The sketch of the simulation domain is shown in Fig. 2(a).
The diameter of the runner bar (label 7 in Fig. 1) is 35 mm. The com-
Region I and II refer to the regions before and after the runner bar
pany noticed that for this particular mould conguration, a certain
gate. A user dened function of the mass ow rate m, which normal
height of alloy in the risers (labels 6 and 8 in Fig. 1) is essential to
to the inlet, was applied as the inlet boundary condition (Dirichlet
ensure to shape the cast. However, this certain height of the alloy
boundary condition). The expression of m with simulation time ts
results in the extra alloy wastage (revert), as shown in Fig. 1.
is shown as following:

2.2. Governing equations and numerical system 0.5 0 ts 10,
m = (7)
The lling behaviour of liquid CoCrW alloy (density , 0 otherwise.
8300 kg m3 , dynamic viscosity , 0.004 kg m1 s1 (Carswell et al.,
m and ts are in the unit of kg s1 and s, respectively. The expression
2011)) in a sand mould was investigated, by using volume of uid
of m is considered a continuous ow feeding the inlet for 10 s and
(VoF) model based on the nite volume technique available in
then the pouring behaviour is stopped to allow for the ow to settle
ANSYS FLUENT (version: 15.0). The liquid alloy ow behaviour
down. For the front outlet and the rear outlet, the outow boundary
is governed by the incompressible ow NavierStokes equations:
condition was adopted, with the ow rate weighting 0.5 and 0.5,
t  + u = 0, (1) respectively. The symmetric boundary condition was applied on the
symmetric plane. The mesh sensitivity test was carried out to make
p 1
t u + (u )u + =  2 u + Fg , (2) sure the simulation results were mesh independent and ensured a
 
good precision at a reasonable computing cost. The ination lay-
where u, p,  and Fg are velocity, pressure gradient, kinematic vis- ers were set in the vicinity of the boundaries with transition ration,
cosity and the gravity force, respectively. VoF model was adopted as maximum layer and growth rate were 0.272, 5 and 1.2, respectively,
the multiphase model to capture the interface between the liquid to capture the uid behaviour near the walls. The unstructured
L. Zhang et al. / Journal of Materials Processing Technology 240 (2017) 249254 251

Fig. 2. The simulation domain (a) and the mesh (b).

Fig. 3. Snapshots of iso-surface of L = 0.5 (in green) and iso-volume of L > 0.5 (in grey) in Region I at different ts . (For interpretation of the references to colour in this gure
legend, the reader is referred to the web version of this article.)

mesh was used, as shown in Fig. 2(b). The total number of the bottom of the choke through the sprue (Fig. 3(a)). The existence of
elements was 142,742. a half nodal-point (Hunt et al., 1978) for the bottom of the choke
wall is observed. The ow then spreads all the directions, whilst
3. Results and discussion it remains attached to the choke bottom wall. In the choke region,
the ow in the x direction forms a recirculation zone, which will
Due to the complexity of the mould conguration, the cavity is be discussed in detail in Section 3.1.2. After the ow reaches the
presented by using two regions: Region I and Region II. The lling choke side wall, the ow level increases along z-axis direction until
behaviour in Region I and II was discussed in Sections 3.1 and 3.2, it reaches the choke top wall (Fig. 3(b)). However, due to the grav-
respectively. ity, the liquid alloy ows back to the bottom part (Fig. 3(c)). The
back ow movement generates the liquid recirculation and the
3.1. Filling behaviour in Region I height of which increases as the lling advances. Once the liquid
level reaches the top wall of the choke region, the interactions
3.1.1. General features between the recirculation ow and the main stream becomes dom-
Fig. 3 showed the snapshots of the interface variation between inant (Fig. 3(d) and (e)). Under this condition, part of the ow ows
the liquid alloy phase and the air phase with ts in Region I: L = 0.5 back to the sprue zone, as shown in Fig. 3(f).
(in green) for iso-surface and at L > 0.5 (in grey) for iso-volume. The Back to Fig. 3(b), for the ow along x direction, as the main-
lling starts whilst the liquid alloy enters the mould from the pour- stream ow towards the runner bar region advances, the ow
ing basin. The ow, driven by the gravity (along z axis), reaches rst meets the step for this particular geometry. This generates an
252 L. Zhang et al. / Journal of Materials Processing Technology 240 (2017) 249254

3.2. Filling behaviour in Region II

3.2.1. General features


Fig. 5 showed the snapshots of the interface variation between
the liquid alloy phase and the air phase with ts in Region II: L = 0.5
(in green) for iso-surface and at L > 0.5 (in grey) for iso-volume. The
mainstream of the liquid alloy rst ows towards the runner bar
end wall, as shown in Fig. 5(a). Due the effect of the runner bar end
wall, a back ow with an opposite direction to the mainstream is
generated. The liquid alloy level in the runner bar region increases
as ts increases. The ow rst enters the rear riser and then the front
riser Fig. 5(b) and (c), respectively. As the lling process advances,
the liquid level in the riser increases. However, for the present con-
guration, the simulation has unveiled an unlled region in the
runner bar, Fig. 5(d), whist the ow has already entered the risers.
Interestingly, after the feeding is stopped (ts > 10 s), there is a clear
indication of the back-ow from both rear and front risers to the
Fig. 4. Snapshots of iso-volume of l > 0.5 (in grey) and surface streamline (in black) runner bar region to rell the unlled volume Fig. 5(e). The lling
at xz plane when y = 0.001 m at different ts .
process is nally completed, as shown in Fig. 5(f) with no existence
of the unlled region.
The results indicate that the shaping time for the cast (runner
bar region) is around 100 s. The total shaping time is nearly 10
anti-clockwise ow recirculation near the step region. At the tur- times compared to the lling time (100 s vs. 10 s). Furthermore, the
ning part of the feeder region, the dynamics of ow is similar with splash behaviour, e.g. back ow originated from the risers, could
the ow past and 90 and 180 sharp bend (Zhang and Potherat, further lead to the oxide lms (Jolly, 2005; Campbell, 2004) and this
2013). The existence of the recirculation is observed near the corner behaviour should be avoided. Therefore, it will be critical impor-
region due to the adverse pressure gradient. After the ow passes tant to reveal the ow behaviour in the nal stage of the lling
through the feeder, the bottom and the turning part of Region I, it process, as the uid dynamics can inuence the microstructure of
reaches Region II. the casting in the region of runner bar and the risers.

3.2.2. Back ow relling behaviour


3.1.2. Flow in the choke The back ow relling process of the unlled volume in the run-
Fig. 4 showed the snapshots of the surface streamline (xz plane ner bar (Fig. 5(e)), identied by the simulation, can not be observed
at y = 0.001 m, which is very close to the symmetric plane) and the in the lling experiment. This is because that the mould cavity is
L > 0.5 (in grey) for iso-volume distribution with ts . At the early entirely covered by the sand. This relling behaviour is driven by a
stage of the lling, an air recirculation, RA , is formed by the shear back ow which originates from the risers due to the gravity effect
layer effect which is caused by the incoming ow, as shown in at the nal stage of the lling process (ts > 10 s).
Fig. 4(a). The intensity of the RA increases with time ts . Once the To capture this phenomenon and understand the ow dynam-
ow ows back under the gravity to the bottom wall of the choke, ics, two cross-sections in the vicinity of inlets of front and rear
as discussed in Section 3.1.1, a liquid alloy recirculating region RL is risers (xz plane at y = 0.035 m) are selected, respectively. The
generated, as shown in (b) and the height of the recirculation region velocity vectors were plotted on the cross-sections at ts = 9.95 s
is increased as the ts increases, whilst the recirculation RA slowly and ts = 10.36 s, as shown in Fig. 6. The reason for the selection
vanishes with rising level of the liquid alloy. As ts advances, e.g. of ts = 9.95 s and ts = 10.36 s is due to the inlet boundary condi-
ts = 2.01 s, as shown in Fig. 4(c), the liquid alloy free level reaches tion, as shown in Eq. (7): the pouring behaviour is stopped at
the top wall of the choke, RL reaches the maximum size and RA ts = 10 s. ts = 9.95 s and ts = 10.36 s denote the moments just before
vortex disappears. and after the pouring stops, respectively. For Fig. 6(a), the ow

Fig. 5. Snapshots of iso-surface of l = 0.5 (in green) and iso-volume of l > 0.5 (in grey) of Region II at different ts . (For interpretation of the references to colour in this gure
legend, the reader is referred to the web version of this article.)
L. Zhang et al. / Journal of Materials Processing Technology 240 (2017) 249254 253

Fig. 6. Distribution of the velocity vectors (normalized) at the surface near the inlets of the risers (xz plane, y = 0.035 m) at different ts .

Fig. 7. Distributions of the iso-volume of L > 0.5 (in grey) and iso-surface L = 0.5 (in green) at different ts . The liquid alloy levels in the risers are decreased and the unlled
volume is relled at ts = 98.6 s compared to ts = 11.6 s. (For interpretation of the references to colour in this gure legend, the reader is referred to the web version of this
article.)

Fig. 8. Sketch of the original (a) and improved (b) conguration. The gates for both risers (blue dashed line region) move towards the direction of outlets of the risers. (For
interpretation of the references to colour in this gure legend, the reader is referred to the web version of this article.)

Fig. 9. Snapshots of the iso-volume of L > 0.5 (in grey) and the iso-surface (in green) at L = 0.5 distribution for different ts in Region II for the improved mould design. (For
interpretation of the references to colour in this gure legend, the reader is referred to the web version of this article.)
254 L. Zhang et al. / Journal of Materials Processing Technology 240 (2017) 249254

vector direction is pointing towards the risers, indicating that the The modied mould design was obtained by varying the gates
ow is entering both risers. However, once the pouring behaviour (between the runner bar and the riser) location, however,
is stopped, a back ow is clearly observed, as shown in Fig. 6(b). remaining the other part features. The modication was expected
This back ow behaviour further results in the decrease of the alloy to be conducted in small scale therefore to minimize the effect
height in both risers, as shown in Fig. 7. Here, h1 (resp. h3 ) and h2 the production process. The results showed that the runner
(resp. h4 ) denote the height of liquid free level in the front (resp. bar unlled volume was disappeared. The alloy wastage were
rear) riser at ts = 11.6 s and ts = 98.6 s, respectively. The result clearly reduced by 11%.
showed that the decrease of free level height in the riser as ts is This research further indicated that the gates location was an
increased. Meanwhile, the unlled volume in the runner bar is lled important parameter need to be considered in detail during the
due to this back ow mechanism. The presence of the hole in the mould design.
front riser, as shown in Fig. 1, could be generated through this back
ow feature and the shrinkage behaviour. Acknowledgements

3.3. Mould conguration modication The authors would like to acknowledge ASTUTE2020 (Advanced
Sustainable Manufacturing Technologies). The Operation has been
The lling simulation for the original sand mould design has part-funded by the European Regional Development Fund (ERDF)
revealed the back ow mechanism to shape the runner bar top through the Welsh Government and the participating Higher Edu-
region. This back ow mechanism requires a certain height of alloy cation Institutes. Additionally, the authors would like to thank
in the risers, which results in the extra alloy wastage. Therefore, Professor Johann Sienz for his helpful discussion and nancial
an modied conguration mould design was suggested, aiming at support. Furthermore, the authors would also like to thank the
eliminate the back ow mechanism so that to reduce the wastage. reviewers for their work which has contributed to this paper.
The modied mould conguration is contrasted to the original
design in Fig. 8. The main difference between the original and the References
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observed in Region II. Fig. 9 showed the snapshots of the interface 606378, Email: info@astutewales.com.
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