Methodology for Thermodynamic Analysis Coupled with Computational Fluid Dynamics Modeling for Casting a Novel Aluminum–Cerium Alloy

In this paper, we present the results of computational fluid dynamics (CFD) analysis to assess castability, porosity, molten metal fluidity and other technological properties of a new Al–Ce alloy. A thermodynamic analysis of a new Al–Ce alloy is done to obtain the physical properties as a function of temperature across both solid and liquid phases. These properties are then used to build the CFD model of the full casting process from initial pouring through to final solidification of the part, here an example of a heavy duty MOR mount is used. This process shows that CFD can be used to assess the capability of the alloy to properly fill the mold, as well as give predictions where scattered porosity or large-scale defects may occur in the casting. Unlike the commercially available software (e.g., ProCAST, SOLIDCast, MAGMASOFT^®) the complex 3D-analysis of the stress/strain fields in cast parts is not performed at this time. The simulation are performed in Star-CCM+ using a volume of fluid analysis. However, the availability of free software for assessing the required thermodynamic/thermo-physical properties of new alloys (OpenCALPHAD) and CFD codes such as OpenFOAM^® makes the developed option attractive and economical to adapt in future, especially for the analysis of new Al–Ce alloys, for which the available data does not exist.