Prediction of Shrinkage Defects in Iron Castings Using a Microporosity Model

Abstract

A numerical model for prediction of shrinkage defects in iron castings has been developed. The model is based on gas pores evolution during solidification. It describes the evolution of gas concentration using mass conservation, and the change in melt pressure due to solidification contraction using Darcy’s equation, with mixture continuity assumption in the liquid and the mushy zone. Gas pores nucleation has been calculated using the partial pressure of gas obtained from Sievert’s law. The growth of porosity has been estimated using an equation based upon the total melt pressure on the pore, concentration and temperature of the gas. The porosity model was calibrated against literature data for microporosity, and then applied to the prediction of shrinkage defects in a ductile iron casting. Comparison between the model predictions and experimental measurements indicated that the porosity model can be applied not only to the prediction of micro-shrinkage but also to that of macro-shrinkage. Existing shrinkage prediction models based upon thermal models, such as Niyama criterion and the modulus of retained melt in mushy regions cannot predict correctly both micro- and macro-shrinkage.