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Cast Iron Solidification Model

FLOW-3D Cast's cast iron model describes the solidification of hypo- and hyper-eutectic iron-carbon-silicon alloys. It predicts the formation of graphite, austenite (or gamma-iron) and carbide phases during the eutectic reaction. Volume changes during cooling and solidification are coupled with shrinkage and porosity formation models. The cast iron model uses a realistic iron freezing path and a chilling susceptibility criterion that controls the local amount of carbide formation.

A simulation of a soldified gray iron casting using FLOW-3D's cast iron model
Carbide (red) and graphite (blue) rich areas in a solidified gray iron casting.

FLOW-3D Cast's cast iron model accounts for the volume changes occurring from the pouring temperature to the solidus: shrinkage during cooling in the liquid state; further shrinkage during pre-eutectic gamma iron formation; subsequent shrinkage or expansion during the eutectic reaction; and the secondary shrinkage from the end of the eutectic reaction to the solidus.

Cast iron filling simulated with computational fluid dynamics software
Gravity filling of a gray iron differential housing casting, with color showing metal temperature