Modeling of porosity formation in direct chill cast aluminum-magnesium alloys

P.D. Lee, R.C. Atwood, R.J. Dashwood, H. Nagaumi

Research output: Contribution to journalArticle

74 Citations (Scopus)

Abstract

A model of the formation of porosity during the DC casting of Al-Mg alloys was developed and incorporated as a post-processor to a commercial transient macromodel of the three dimensional heat transfer and fluid flow. The porosity model not only predicts the percentage porosity, but also the size, shape and distribution of the pores. The sensitivity of the model to process and alloy variations was evaluated, showing the importance of the cooling rate and hydrogen concentration. An experimental study of the amount of porosity in laboratory scale (250 × 400 mm cross-section) DC cast ingots of Al 2, 4 and 6 wt.% Mg was performed. The results from these experimental billets were used to validate the model as a function of the location in the ingot and the initial hydrogen and magnesium content. The model correctly predicted the experimentally observed trends, showing good correlation to the measured percentage porosity. © 2002 Elsevier Science B.V. All rights reserved.
Original languageEnglish
Pages (from-to)213-222
Number of pages10
JournalMaterials Science and Engineering A
Volume328
Issue number1
Early online date25 Mar 2002
DOIs
Publication statusPublished - May 2002

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magnesium alloys
Magnesium alloys
aluminum alloys
casts
Aluminum alloys
Porosity
porosity
Ingots
ingots
Hydrogen
direct current
billets
Magnesium
hydrogen
Flow of fluids
Casting
fluid flow
central processing units
magnesium
Heat transfer

Keywords

  • Direct chill casting
  • Porosity
  • Modeling
  • Al–Mg alloys

Cite this

Modeling of porosity formation in direct chill cast aluminum-magnesium alloys. / Lee, P.D.; Atwood, R.C.; Dashwood, R.J.; Nagaumi, H.

In: Materials Science and Engineering A, Vol. 328, No. 1, 05.2002, p. 213-222.

Research output: Contribution to journalArticle

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AB - A model of the formation of porosity during the DC casting of Al-Mg alloys was developed and incorporated as a post-processor to a commercial transient macromodel of the three dimensional heat transfer and fluid flow. The porosity model not only predicts the percentage porosity, but also the size, shape and distribution of the pores. The sensitivity of the model to process and alloy variations was evaluated, showing the importance of the cooling rate and hydrogen concentration. An experimental study of the amount of porosity in laboratory scale (250 × 400 mm cross-section) DC cast ingots of Al 2, 4 and 6 wt.% Mg was performed. The results from these experimental billets were used to validate the model as a function of the location in the ingot and the initial hydrogen and magnesium content. The model correctly predicted the experimentally observed trends, showing good correlation to the measured percentage porosity. © 2002 Elsevier Science B.V. All rights reserved.

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