Liquid Metal Feeding: Quantifying its role on defect formation

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Light metals usage in the automotive and transportation industries continues to increase with the demand for improved fuel economy and performance through weight savings. Cast light metal products have shown good market penetration by replacing ferrous based components such as cylinder heads and through part consolidation. While light metals usage may advance vehicle energy efficiency, continuous improvement is needed in the manufacturing processes to increase yield and production energy efficiency. The development of strategies to eliminate casting defects has historically been a trial and error process. However, the continued increase in computational capabilities has led to the use of mathematical models to improve casting design, providing quantitative knowledge of casting systems. The proposed research program is focused on developing new and fundamental knowledge related to the susceptibility of model (binary) and commercial alloys to form three casting defects: i) macrosegregation, ii) macroporosity, and iii) surface depressions. All three of these defects are intimately related to liquid metal feeding during solidification. A combined approach involving experimental castings and mathematical modeling is proposed to generate necessary knowledge and to develop computational tools to quantify the susceptibility of metallic alloys to form liquid metal feeding related defects. The continued development of new knowledge relevant to the casting industry is critical to maintaining this competitive advantage. Developing a more fundamental understanding of liquid metal feeding defects and developing tools to quantitatively predict their formation will ultimately lead to better castings and more efficient casting processes. This will enable Canadian manufacturing companies to remain competitive while facing increasing pressure from offshore manufacturers.