The Challenge and Progress in Macro- and Micro-modeling and Simulation of Squeeze Casting Process

Jiale Ma, Zhiqiang Han, Anil K. Sachdev, Alan A. Luo
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Abstract

Squeeze casting is an advanced manufacturing process for aluminum and magnesium alloys, which produces high integrity and heat-treatable cast components. The physics involved in squeeze casting is pressurized solidification and it is important to understand the fundamental knowledge of pressurized solidification and to develop numerical models both at macro- and micro-scales. This review presents the major challenge and novel research dedicated to macro- and micro-modeling on squeeze casting of aluminum and magnesium alloys, including metal displacement and free surface tracking, thermal–mechanical coupled simulation, casting–mold interfacial heat transfer model, shrinkage defect and macrosegregation prediction, pressurized solidification and microstructure modeling, through-process modeling, etc. Finally, the prospects of the macro- and micro-modeling on squeeze casting process are presented.

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挤压铸造工艺宏观和微观建模与仿真的挑战与进展
挤压铸造是一种先进的铝镁合金制造工艺,可生产出完整性高且可进行热处理的铸造部件。挤压铸造所涉及的物理学原理是加压凝固,因此了解加压凝固的基本知识以及开发宏观和微观尺度的数值模型非常重要。本综述介绍了铝镁合金挤压铸造宏观和微观建模的主要挑战和创新研究,包括金属位移和自由表面跟踪、热机械耦合模拟、铸造-模具界面传热模型、收缩缺陷和宏观偏析预测、加压凝固和微观结构建模、全过程建模等。最后,介绍了宏观和微观建模在挤压铸造过程中的应用前景。
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