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Casting Design For The Study Of Porosity Formation In Aluminum Alloys

IP.com Disclosure Number: IPCOM000009061D
Publication Date: 2002-Aug-05
Document File: 1 page(s) / 50K

Publishing Venue

The IP.com Prior Art Database

Abstract

Cast aluminum components are replacing cast iron in many automotive engine applications. In order to decrease development time, computer models are being developed to predict durability and manufacturing capability of a given design to reduce the number of design iterations currently required.

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Casting Design For The Study Of Porosity Formation In Aluminum Alloys

Cast aluminum components are replacing cast iron in many automotive engine applications. In order to decrease development time, computer models are being developed to predict durability and manufacturing capability of a given design to reduce the number of design iterations currently required. Cast aluminum components generally contain some level of porosity due to the characteristics of aluminum. Porosity has been identified as the single most significant factor in determining the durability of a cast aluminum component. Therefore, it is critical to develop models that can be used in the computer simulations to predict the location and amount of porosity that forms in a cast component in order to predict the durability of a cast component. The development and validation of these models require experimental data collected on castings made under very controlled conditions. The complex shape of cast components makes it very difficult to quantify the porosity distribution. In addition, the computation time required to analyze actual components is long. What is needed is a casting design that is complex enough to exhibit a range of casting conditions while being simple enough to be quick and easy to analyze using computer-based casting simulations.  A modular casting design (the dumbbell) has been developed to do this. It has a very simple geometry so it is easy to mesh for finite element analysis, is easy to characterize us...