Investigations on the Melt Flow Behavior and Microstructure of A390 Alloy During Vertical Centrifugal Casting Process: C
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ORIGINAL ARTICLE
Investigations on the Melt Flow Behavior and Microstructure of A390 Alloy During Vertical Centrifugal Casting Process: CFD Simulation and Experiments Akhil S. Karun1 • J. Aneesh Kumar2 • T. S. Jeyalakshmi3 • B. Sai Gopal Krishna3 K. S. Vignesh Suraj3 • Karthik V. Shankar3 • T. P. D. Rajan1 • S. Savithri2
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Received: 21 March 2020 / Accepted: 29 June 2020 Ó The Indian Institute of Metals - IIM 2020
Abstract In this study, vertical centrifugal casting process is used for the fabrication of functionally graded A390 alloy hollow cylinder and Mg & Sr-included A390 alloy hollow cylinder. The commercial CFD software FLOW3DTM is used to obtain the optimum rotational speed for making an optimized hollow cylinder in a vertical centrifugal casting machine. The optimum rotational speed obtained is 1300 rpm. This rotational speed is used in the experiments to obtain hollow cylinders of optimized thickness for (a) A390 alloy (b) by adding various weight percentages of Mg and Sr in A390 alloy. The optical microstructures obtained at various radial locations are presented for centrifugally cast A390 alloy. The effect of individual addition of Mg & Sr into A390 alloy on the microstructures at various locations along the radial direction of centrifugally cast cylinder is discussed in detail. Keywords Centrifugal casting A390 alloy CFD simulation Mold filling Heat transfer Solidification
& S. Savithri [email protected]; [email protected] 1
Materials Science and Technology Division, CSIR-National Institute for Interdisciplinary Science and Technology, Thiruvananthapuram, Kerala 695019, India
2
Computational Modeling and Simulation Group, Materials Science and Technology Division, CSIR-National Institute for Interdisciplinary Science and Technology, Thiruvananthapuram, Kerala 695019, India
3
Department of Mechanical Engineering, Amrita Vishwa Vidyapeetham, Amritapuri, Kerala 690525, India
1 Introduction Lightweight hypereutectic Al–Si alloys are used as structural materials for various engineering applications due to (a) their high wear resistance and low coefficient of thermal expansion, (b) their physical properties which are influenced by their chemical composition and (c) the improved mechanical properties which are influenced by the microstructure and the composition of the alloy [1–4]. Because of good castability, these alloys are widely used in the field of automobile and general engineering industry [5–7]. The superior mechanical properties of hypereutectic Al–Si alloys depend on the size and shape of the primary silicon [8]. Nowadays, different aluminum alloys with varying percentages of silicon and other constituent elements are extensively used for the manufacturing of functionally graded materials of desired properties. Moreover, the structure and properties of the alloys not only depend on the chemical composition but also on many factors that act during the time of solidification. Centrifugal casting is one of the simplest methods for the production of functionally graded m
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