Alloy Solidification Analysis

Several researchers have conducted studies to evaluate solidification analysis of micro-scale metallic particles through various methods and techniques.

Shih-Lung Lin and Jehnming Lin, two researchers at the Laser Precision Engineering Laboratory, Department of Mechanical Engineering, National Cheng Kung University, Tainan, Taiwan, jointly conducted a study to analyze the solidification process in metallic particles and cast products.

The researchers used the laser supersonic heating technique, to conduct the study and perform solidification analysis in metallic particles and cast products. Mathematical model was established, to analyze the velocity temperature and solidification processes in metallic particles and cast products. The researchers also formulated a numerical analysis method, to generate the flow field structure of shock waves, leading to conducting other related investigations.

Metal Technologies Inc. Product engineering center has also developed the latest solidification analysis software, called Magmasoft, to identify flow problems and solidification, correcting them before tooling is cut. The new software can also replicate shrink areas, internal stress in the part, sand mold erosion, and cooling gradients in addition to performing solidification analysis of micro metallic particles.

The company operates the new software on the very fast NT machines that provide a window for its engineers within the mold, enabling them to forecast the metal casting result, before a single iron drop is poured. The company also uses the new software, to launch a range of new solidification analysis products.

A team of scientists from Japan proposed a hybrid finite difference method (FDM) in 1991, to perform finite difference solidification analysis. The hybrid method was also used to investigate the co-existence of the reduction of calculation time required for solidification analysis and its accuracy. The estimated calculation time varied significantly from the results of the study, without affecting macro shrinkage porosity in the hybrid method applied FDM solidification analysis.

Another new meshing technique has also been developed that utilizes the geometric elasticity of the Finite Element Method (FEM), to get exact results for the metal casting and die or mold.

The new mesh technique, along with a well-organized solidification analysis program, enables large complex automobile castings to be examined with minimum computer resources requirements.

Several other scientists are also involved in performing solidification analysis of secondary cooling and bulging of cast strands.

Several other scientists are also using Newton and Fourier analysis tools to perform thermal investigations and solidification analysis in metallic particles and cast products. The Newtonian method enables researchers, to predict maximum heat generation during solidification process in metallic particles and cast products, while the Fourier method helps in integrating thermal gradient effects and predict s heat generation peaks during solidification processes.

It is expected that continuous research and the development of the latest tools, methods, software, and techniques will enable engineers, to perform accurate solidification analysis of metallic particles.

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