Analysis of the Penetration Behavior of Molten Cast Iron into the Sand Mold

Abstract

An evaluation method for the initial penetration of molten cast iron into the sand mold was suggested based on the laboratory-scale penetration experiments for the cast iron. The horizontal penetration depth of the molten cast iron into the sand core was analyzed using the capillary model. The early stage of the penetration was discussed, and it was clarified that the penetration is not stopped by the solidification but is stopped by the decreasing of the equivalent pore radius. It was explained that the equivalent pore radius decreases with increasing the penetration depth, and the penetration is stopped when the critical pressure, i.e., the pressure required for the penetration, becomes higher than the pressure which is acting on the penetration front. Based on the analysis, an evaluation method of the penetration of depth at the early stage of the penetration was suggested. The analysis method was applied for the other type of metals (mercury and steel) as well, and reasonable results were obtained. A simplified finite-element model of liquid iron penetration into a sand core was developed, accounting for heat exchange between the melt and the porous medium, at different pore geometries.