A New Model for Predicting Oxide-Related Defects in Aluminum Castings
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, KEITH RIPPLINGER, DUANE DETWILER, and A.A. LUO
The formation of oxide-related defects, including entrained oxide inclusions and oxide-induced gas/shrinkage porosity, during cavity fill and solidification has been inextricably linked to reduced mechanical properties in aluminum castings. Although the oxide formation and entrainment process can be easily understood, it remains difficult to accurately predict the location and severity of oxide-related defects in solidification products. To address the lack of predictive capability, the oxide entrainment number (OEN) model was developed and coupled to a three-dimensional, computational fluid dynamics software to accurately predict both the location and severity of oxide-related defects in aluminum castings. This first computationally efficient model for such application was validated on a geometrically complex aluminum casting where the predictive capability was confirmed via X-ray computed tomography (CT). Additionally, the OEN model can be used to aid in location-specific property prediction as tensile samples taken from the casting showed a reduction in mechanical properties in regions of high defect concentrations predicted by the OEN. The validation of the new OEN model provides a crucial link in an integrated computation materials engineering framework for design and manufacturing of high-quality cast components. https://doi.org/10.1007/s11663-020-01918-5 The Minerals, Metals & Materials Society and ASM International 2020
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INTRODUCTION
THE desire for lighter, stronger, more durable castings has been a persistent goal of cast metals research for many decades. However, hindering this goal has been the presence of defects within the cast structures. Defects, such as porosity, pin holes, hot tears, and inclusions, have plagued foundries, causing a reduction in mechanical properties, and often led to an increased scrap rate. Of these defects, entrained oxide inclusions or bifilms are some of the most deleterious to aluminum castings. Entrained oxide inclusions are often too small to detect via conventional nondestructive examination, while the cracklike morphology of entrained inclusions often results in a reduction in mechanical properties.
COLIN. D. RIDGEWAY is with the Department of Materials Science and Engineering, The Ohio State University, 2041 College Road North, Columbus, OH 43210. KEITH RIPPLINGER is with the Honda Engineering North America, 12500 Meranda Rd, Anna, OH 45302. DUANE DETWILER is with the Honda R&D Americas, Inc. 21001 State Route 739, Raymond, OH 43067, USA. A.A. LUO is with the Department of Materials Science and Engineering, The Ohio State University and also with the Department of Integrated Systems Engineering, The Ohio State University, 1971 Neil Ave, Columbus, OH 43210, USA. Contact e-mail: [email protected]. Manuscript submitted April 1, 2020.
METALLURGICAL AND MATERIALS TRANSACTIONS B
Aluminum castings particularly suffer due to the high affinity of molten aluminum to react with various gases (such as oxygen, hydrogen, and moisture), result
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