Numerical Simulation of Infiltration and Solidification Processes for Squeeze Cast Al Composites with Parametric Study

Abstract

An axisymmetric finite element (FE) model is developed for the process of squeeze casting the metal-matrix composites (MMCs). The flow in the mold, the infiltration into the porous preform, and the solidification of the molten metal are studied numerically. The saturated porous flow model is adopted to simulate metal infiltration into the fibrous preform. To track the fluid front during the mold filling and infiltration, the level-set method is used. The enthalpy method is used to deal with transient heat transfer, including phase changes. Also, a simple preform deformation model is used to predict the permeability change caused by preform compression during infiltration. A numerical model representing the experiment setup is proposed. The infiltration and cooling behaviors during a process were calculated using pure aluminum as the matrix and a Saffil fiber preform. To validate the assumptions used in the numerical model, a series of infiltration experiments was carried out. The infiltration kinetics and the preform deformation were studied at different inlet pressures and at different preheat temperatures of the aluminum and the mold. A comparison with the experimental data shows that the developed FE program successfully predicts the actual squeeze casting process.