Abstract
Bifilms have been proposed to be critical for forming casting defects. The reduced pressure test (RPT) and bifilm index (BI) have been widely studied and used in industry for melt quality assessment. However, the BI remains challenged in predicting the mechanical properties. This work investigated the usage of RPT for elongation prediction by analyzing the melt in two foundries. The results showed that the BI could be valid when the bifilms exist as fully inflated pores. In reality, bifilms present as pores with various morphology and distribution, generating local stress concentrations under tension. Consequently, the parameter areaeff, which considers the pores’ morphology and distribution, was proposed, and the resultant feff showed a good correlation with the elongation of the castings. These results guide the foundry to predict the elongation of the final castings and give directions for further research on the bifilm defects.
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