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The Quantitative Assessment of Casting Quality Using CFD

Researcher: Nick Humphreys (now of Doncasters Group)

Collaborators: Bill Griffiths, Robert Watson

For film forming alloys such as aluminium, past research has shown that the surface turbulence encountered when filling large, complex components causes the entrainment of oxide bi-films, which act as predefined cracks in the otherwise sound casting. As part of a Technology Strategy Board (TSB) project, to introduce innovative aluminium casting alloys and related processing know-how in aerospace, automotive and similar sectors, the focus of the university’s research is the ongoing development of an in-house numerical algorithm, which is applied to a commercial CFD code, in order that the quality of a cast component can be assessed in a quantitative manner. By adding discrete particles to represent the oxide bi-films, defects can be tracked through the fluid domain without numerical diffusion blunting the later analysis of casting quality.

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