Contents

Casting
Meeting Future Challenges in Shape Casting Process Simulation

Marc C. Schneider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cyclone-Based System for Cleaning Liquid Aluminum of Solid Inclusions: Numerical Study

Laurens Katgerman; Dmitry G. Eskin; Andrey N. Turchin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Simulation Based Optimization Strategy for Balancing Quality and

Productivity in Continuous Casting

Wilfried Schaefer; Goetz Hartmann; Erik Hepp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Simulation of Semi-Solid Feed Stock Formation in Cooling Channel Rheocasting Process

Mahmoud Ahmadein; Emir Subasic; Matthias Bnck; Bjrn Pustal; Andreas Bhrig-Polaczek . . . . . . . . 29

From Conception to Mechanical Properties Optimization Effect of the Microstructure

and Defects on Thermomechanical Calculations During Casting and Heat Treatment

Gael Couturier; Jiri Kovarik; Alain Jacot; Josef Barta; Mark Samonds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Mathematical Modeling of a Superlight Magnesium Slab During the Start-Up

Phase of the Direct Chill Casting Process

Hai Hao; Shan Yao; Xingguo Zhang; Shuyan Shi; Junze Jin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Modelling Oscillation Mark Formation and Slag Infiltration Through the Coupling
of Multiple Physical Phenomena During Continuous Casting

Pavel E. Ramirez Lopez; Peter D. Lee; Kenneth C. Mills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Modelling the Tilt-Casting Process for the Tranquil Filling of Titanium

Alloy Turbine Blades

Hong Wang; Georgi Djambazov; Koulis A. Pericleous; Richard A. Harding; Michael Wickins . . . . . . . . . . . . 61

New Insights into the Electro-Slag Remelting Process using Mathematical Modeling

Ashish D. Patel; Kanchan M. Kelkar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Centrifugal Casting of Complex Geometries: Computational Modelling

and Validation Experiments

Dmytro Shevchenko; Diane McBride; Nick Humphreys; Nick Croft;

Paul Withey; Nick Green; Mark Cross . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Coupling / Multi-physics
Coupling In-situ Observations and Microscale Modeling to Predict Pore and Fe-rich
Intermetallic Formation during the Solidification of Al-Si-Cu-Fe Alloys

P. Lee; J. Wang; M. Li . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Bridging the Gap Between Manufacturing Reality and Design Assumptions:

Chaining Manufacturing Analyses and Defects with Performance Testing

Adi Sholapurwalla; Sam Scott . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

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Modeling of Mechanical Contact Conditions in Casting

Jrg Klinkhammer; Jesper Thorborg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Phase-Field Simulation of Equiaxed Solidification: A Homoenthalpic Approach to

the Micro-Macro Problem

Bernd Bttger; Markus Apel; Janin Eiken; Philippe Schaffnit; Georg J. Schmitz; Ingo Steinbach . . . . . . . 119

On Modelling of Microstructure Formation, Local Mechanical Properties and Stress

Strain Development in Aluminium Castings

Ingvar L. Svensson; Salem Seifeddine; Jesper Hattel; Petr Kotas; Jesper Thorborg . . . . . . . . . . . . . . . . . . . . 129

Explicit Coupled Thermo-Mechanical Finite-Element Model of Continuous

Casting of Steel in Funnel Molds

Seid Koric; Lance Hibbeler; Brian G. Thomas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Ultrasonic Technology Model Development and Applications to Casting Processes

Laurentiu Nastac . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

A Unified Elasto-Viscoplastic Constitutive Model of Grey Cast Iron

Chunsheng Li; Richard K. Huff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

The Influence of the Morphology Evolution of Free-Floating Equiaxed Grains on

the Macrosegregation In A 3.3-Ton Steel Ingot

Miha Zalonik; Herv Combeau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Mould Taper Optimization for Continuous Casting Steels by Solidification

Shrinkage Simulation

Shaowu Cai; Tongmin Wang; Jun Li; Jingjing Xu; Yanyan Du; Dawei Luo; Tingju Li; Junze Jin . . . . . . . . . . 173

Modeling of Infiltration Casting of Cellular Magnesium Alloy

Hai Hao; Jie Cui; Shuyan Shi; Xingguo Zhang; Shan Yao; Junze Jin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Numerical Simulation on Magnetic Penetrating Performance of Soft-Contact

Eletromagnetic Casting Rectangular Mould for Duraluminium Alloys

Jun Li; Yanyan Du; Tongmin Wang; Jingjing Xu; Shaowu Cai; Jiachun Wang;
Zhiqiang Cao; Tingju Li; Junze Jin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Numerical Simulation of Thermal and Flow Fields in Induction Skull Melting Process

Tongmin Wang; Yanqing Su; Guanxia Xue; Jingjing Xu; Shaowu Cai; Jun Li;
Zongning Chen; Jingjie Guo; Tingju Li; Junze Jin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Modelling the Interaction of Particles with a Concave Solidifying Interface

Eliana M. Agaliotis; Mario R. Rosenberger; Alicia E. Ares; Carlos E. Schvezov . . . . . . . . . . . . . . . . . . . . . . . . . 209

Numerical Methods / Segregation

Micro-Macrosegregation Prediction Based on Solidification Simulation for
Continuous Casting of Ternary Bronze Alloys

Monika Grasser; Anton Ishmurzin; Florian Mayer; Menguai Wu;

Andreas Ludwig; U. Hofmann; J. Riedle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Seamless Simulation from Fluid Flow to Solidification Using New Moving

Particle Semi-Implicit (MPS) Method

Naoya Hirata; Koichi Anzai . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

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Experimental Study of Contributions of Different Grain Structures to

Macrosegregation in Aluminum Alloys

Dmitry G. Eskin; Laurens Katgerman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Observation of the Segregation by Using Time-resolved X-ray Imaging

Hideyuki Yasuda; Yosuke Yamamoto; Noriaki Nakatsuka; Masato Yoshiya;

Tomoya Nagira; Akira Sugiyama; Itsuo Ohnaka; Kentaro Uesugi; Keiji Umetani . . . . . . . . . . . . . . . . . . . . . 245

Effects of Solidification Kinetics and Liquid Density in Modeling of

Macrosegregation In Castings

Miha Zalonik; Herv Combeau . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Simulation of Alloyed Cast Iron On Process and Material Scale: A Physics

and Calphad Based Approach

Bjoern Pustal; H. Siebert; Emir Subasic; Bengt Hallstedt; Jochen M. Schneider;

Andreas Buehrig-Polaczek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

Micro- and Macro-segregation of a Peritectic Au-Fe Alloy during Bridgman Solidification

Denis Favez; Michel Rappaz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Study of Centerline Macrosegregation in Steel Continuous Casting with a

Two-Phase Volume Averaging Approach

Florian Mayer; Menghuai Wu; Andreas Ludwig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

Casting Simulation for Robust Design of Process Parameters Using

Quality Engineering Approach

Akihiko Kimatsuka; Itsuo Ohnaka; Yuriko Saito; Yasunori Kuroki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Finite Element Thermomechanical Simulation of Steel Continuous Casting

Romain Forestier; Frdric Costes; Olivier Jaouen; Michel Bellet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Simplified Three-dimensional Macro Segregation Simulation Model and its

Application to Directional Solidification of Sn-Bi Alloys

Tomoki Sawada; Katsunari Oikawa; Koichi Anzai . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Defect Formation
Simulation of Deformation and Hot Tear Formation Using a Visco-Plastic
Model with Damage

Charles A. Monroe; Christoph Beckermann; Joerg Klinkhammer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

A Feeding Flow Related Model for Modelling Shrinkage Defects

Zhian Xu; Ana Rosanete L. Reis; Rob Van Tol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Prediction of Hot Tear Defects in Steel Castings Using a Damage Based Model

Zhiping Lin; Richard K. Huff; Charlie A. Monroe; Christoph Beckermann . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Modeling of Shrinkage Porosity Formation and its Validation

Jianzheng Guo; Ade Makinde; Bernard Bewlay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

A Model for Binder Gas Generation and Transport in Sand Cores and Molds

Andrei J. Starobin; Cyrill W. Hirt; D. Goettsch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

A 3D Granular Model of Equiaxed-Granular Solidification

A B. Phillion; J-L Desbiolles; M Rappaz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

Prediction of Casting Defects in High-Pressure Die Casting Processes by Using JSCAST

J. D. Zhu; H. Yokoyama; I. Ohnaka; T. Murakami; S. L. Cockcroft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

A Phase Field Model for a Geometrical Description of Micropores Constrained

by a Solid Network

Milan Felberbaum; Alain Jacot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

Numerical Predictions of Gas Porosity in Industrial Casting Processes using Fully

Coupled Mold-Filling and Solidification Simulation

Santhanu Jana; Juergen Jakumeit; Mohamed Y. Jouani . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377

Modeling of Porosity Size Distribution in A356 Tapered Cylinder Castings

L. Yao, E. Khajeh, S.L. Cockcroft, D.M. Maijer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

Modeling of Reoxidation Inclusion Formation in Steel Sand Casting

Antonio J. Melendez; Kent D. Carlson; Christoph Beckermann; Marc C. Schneider . . . . . . . . . . . . . . . . . . . 393

Fluid Flow
Improvement of Mold Filling Simulation

Itsuo Ohnaka; A. Sugiyama; J. D. Zhu; F. Kinoshita . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403

Micro Droplet Behaviors of Molten Lead Free Solder Using Inkjet Printing Technique

Ming-Hsiu Tsai; Weng-Sing Hwang; Weng-Chung Sung; Hsin-Hung Chou . . . . . . . . . . . . . . . . . . . . . . . . . . 411

Using the Calculated Froude Number for Quality Assessment of Casting Filling Methods

Carl Reilly; Nick Green; J. C. Gebelin; Mark Jolly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

Influence of the Gas Phase on Mold Filling for Sand Casting

Juergen Jakumeit; Kevin Goodheart; M. Albers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

Computational Methods for Mold Filling Simulation of Semi-Solid Alloys

Jean-Franois Htu; Florin Ilinca . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435

Investigating Surface Entrainment Events using CFD for the Assessment of

Casting Filling Methods

Carl Reilly; Mark Jolly; Nick Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443

Three-Dimensional Simulation of The Influence of Convection on Dendritic Solidification

Lang Yuan; Peter D. Lee; Georgi Djambazov; Koulis A. Pericleous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

Complex Free Surface Flows for Mould Filling Using Centrifugal Casting

Diane McBride; Nick Humphreys; Nick Croft; Nick R. Green; Mark Cross . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459

Diagnosis Parameter of Mold Filling Pattern of Molten Metal for the Casting System

Jun Ho Hong; Young Sim Choi; Ho Young Hwang; Jeong Kil Choi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467

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Micro and Macrostructure Formation

An Inverse Growth Restriction Model for Predicting Solidified Grain Size

D H. StJohn; M A. Easton; Ma Qian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477

Simulation of Solidification Grain Structures with a Multiple Diffusion

Length Scales Model

Salem Mosbah; Michel Bellet; Charles-Andre Gandin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485

Effects of Geometric Constraints on Alloy Solidification in Metal-Matrix Composites

Rui Shao; Kevin P. Trumble; Matthew J. Krane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 495

Modeling of Ferrite Growth in Compacted Graphite Iron

Mathias Knig; Ingvar L. Svensson; Magnus Wessn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

A Combined Experimental-Model Approach to Estimate the Solidification Macrostructures

Formed During a Microgravity Experiment on Ti-Al Based Intermetallic Alloys

Shaun McFadden; David J. Browne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513

Thermoelectric Effects on Alloy Solidification Microstructure

Andrew Kao; Koulis A. Pericleous; Mayur K. Patel; Vaughan R. Voller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521

Modeling of Solutal Dendritic Growth in Three Dimensions

Shiyan Pan; Mingfang Zhu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 529

Using a Five-Phase Volume Averaging Approach to Model the Mixed

Columnar-Equiaxed Solidification

Menghuai Wu; Andreas Ludwig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 537

Phase Field Modelling of Twinned Dendrite Growth

Mario A. Salgado; Jean-Luc Desbiolles; Michel Rappaz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545

Numerical and Experimental Investigation of Dendritic Growth Texture Evolution

in Mg-Al alloys with Hcp-Lattice Anisotropy

Janin Eiken; Gerald Klaus; D. Mirkovic; Ingo Steinbach;

Andreas Bhrig-Polaczek; R. Schmid-Fetzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 553

Welding
New Numerical Technologies for the Simulation of Arc Welding Processes

Michel Bellet; Makhlouf Hamide; Christel Pequet; Patrice Lasne . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563

Modelling the Development of Stresses During Single and Multipass

Welding of a Ferritic Steel in an Instrumented Restraint Cracking Test

H.G. Fjr; R. Aune; Mohammed MHamdi; O.M. Akselsen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 571

Using Numerical Simulation to Predict the Distortion of Large Multi-Pass

Welded Assemblies

Josef Tejc; Ji Kova k; Vclav Zednk; Adi Sholapurwalla; Madhu Nannapuraju;

Harald Porzner; Frederick Boitout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579

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Predicting Homogeneity of WC-Based Metal Matrix Composites Deposited

by Plasma Transferred Arc Welding

T.B. Wolfe; Hani Henein . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585

Phenomena in Solidification Modeling and Validation

Microsegregation Modeling of Multiple Phase Transformations
Atomization of Al-Ni Alloys

Damien Tourret; Charles-Andre Gandin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603

In-Situ Study on Dendritic Growth of Sn-Bi Alloys By Diffraction-Enhangced X-Ray Imaging

Tongmin Wang; Jingjing Xu; Wanxia Huang; Jun Li; Shaowu Cai; Tingju Li; Junze Jin . . . . . . . . . . . . . . . . . 613

Phase Field Modelling on Microsegregation During Solidification of An Al-Cu Binary Alloy

Qiang Du . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619

Phase Field Modeling of Equilibrium Shapes and Growth Morphologies in Al-Zn Alloys

Jonathan M. Friedli; Michel Rappaz; Aule Mariaux; Frdric Gonzales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 627

Solidification Path of Al-Fe-Mn-Si Aluminium Alloys

Jacques Lacaze; Luiz Eleno; Bo Sundman . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635

Modeling and in-Situ X-Ray Video Microscopy of Confined Equiaxed Grain

Growth and Buoyant Motion in Al-Cu

P. Delaleau; R. H. Mathiesen; P. L. Schaffer; L. . Arnberg; C. . Beckermann . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 643

Modelling of Macrosegregation in Multicomponent Aluminium Alloys

K. Ellingsen; A. L. Dons; M. MHamdi; D. Mortensen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 651

Mechanical Properties of Zinc Aluminum Alloys Versus Structural

and Thermal Parameters

Alicia E. Ares; Isaura P. Gatti; Sergio F. Gueijman; Carlos E. Schvezov . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 659

Modeling Nucleation and Growth of Zinc Grains in Hot-Dip Galvanized Coatings

Aurle Mariaux; Tom Van De Putte; Michel Rappaz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 667

Validation of a Porosity Nucleation Model by X-ray Tomography

Amaury Chabod; Yves Gaillard; Grald Ogier; Valrie Bueucher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 675

Numerical and Experimental Characterization of a Cast Bell

Didier Linxe; Patrick Priot; Michel Stucky; Michel Elary; Jean-Marie Dracon; Luigi Bergamo . . . . . . . . . . 683

Author Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 693

xiii