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Casting Defect Prediction - Entrained Air

The air entrainment model in FLOW-3D Cast is used to estimate the amount of entrained air occurring in metal casting systems, such as gravity-poured casting processes. It is based on simple physical mechanisms, which means it can also be used to estimate the amount of entrained air occurring in metal casting systems, such as gravity-poured casting processes. Recent additions of even more physical details in the model allow entrained air, which is assumed to be in the form of bubbles, to be modeled as rising in the surrounding liquid because of buoyancy forces and even leaving the liquid if it reaches a free surface.

CFD simulation of air entrainment using FLOW-3D Cast

A front gear housing, 380 die cast alloy. Results are colored by percent of entrained air. Image courtesy of Albany-Chicago Co.

CFD die casting simulation predicting air entrainment using FLOW-3D Cast

A support arm cast in A380. Result is colored by air entrainment. The major concern with the part was filling the deep and thin ribs. Image courtesy of Littler Diecast Co.

Related links:

Air Entrainment Validation
Making the Switch: Improving High Pressure Die Casting Designs

 

High Pressure Die Casting Hot Chamber Runner and Gate Design to Reduce Air Entrapment

High Pressure Die Casting Hot Chamber Runner and Gate Design
Four different simulation cases of the Caster Wheel Leg part were run. These parts are made of Zinc alloy #5. Three cases 1-3 had different runners and all four cases had different sized overflows at different locations. Case 4 showed the best gating and overflow design to eliminate air entrapment. Casting simulation results courtesy of Deco Products. Simulation post-processed with FlowSight, coming soon in FLOW-3D v11.