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Metals
Special Issues
Modeling and Simulation of Solidification and Casting
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Modeling and Simulation of Solidification and Casting

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: closed (30 September 2022) | Viewed by 10458

Special Issue Editor

Prof. Dr. Henry Hu

E-Mail Website
Guest Editor
Department of Mechanical, Materials & Automotive Engineering, University of Windsor, 401 Sunset Ave. Windsor, ON N9B 3P4, Canada
Interests: mathematical modeling; numerical simulation; light alloys; magnesium; aluminum; composites; solidification phenomena; casting; microstructure development; defect formation; mechanical properties

Special Issue Information

Dear Colleagues,

With the advent of advanced and powerful computer hardware and software, mathematical modeling and numerical simulation have progressed into the modern era and become increasingly popular in the past twenty years. Meanwhile, novel casting and metallurgical processes for both ferrous and nonferrous materials are constantly emerging. Computer modeling has become an important tool for not only the improvement of conventional processes but also the development of advanced technologies. Numerical simulation can eliminate primitive, time-consuming, and costly experimental trials for process optimization with an appropriate set of process parameters. In particular, simulation enables envisioning the sequences of cavity filling, solidification, microstructure evolution, and defect formation in the casting and metallurgical processes, which are almost impossible to observe experimentally .  

The aim of this Special Issue is to present the latest achievements in modeling, numerical simulation, and observation of solidification and relevant technologies coupled to casting and metallurgical processes. The topics to be covered by this issue include solidification processing of metallic alloys (steel, cast iron, Al, Cu, Mg, Ti, and other ferrous and nonferrous alloys) and their composites; shape casting (high pressure die casting, sand casting, permanent mold, thixocasting, rheocasting, lost foam, etc.); continuous casting; processing/structure/property relations, numerical methods for cavity filling, and solidification modeling; nucleation, grain refinement, and inoculation techniques; microstructure evolution and modification; in situ observations of solidification phenomena and comparison with predictions; micro- and macrosegregation; thermodynamics of solidification; stress and deformation; defect formation (hot tearing, macroshrinkage, and porosity); novel process techniques (additive manufacturing and 3D printing); treatment after casting (e.g., heat treatment, machining, shot peening); and mold and core materials (e.g., thermal conductivity, specific heat, density, mechanical properties).

This Special Issue provides an excellent platform for leading academics, researchers, and engineers from all over the world to unveil their latest scientific discoveries with respect to modeling, simulation, and experimental observations of solidification and related metallurgical phenomena.

Prof. Dr. Henry Hu
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • mathematical modeling
  • numerical simulation
  • ferrous and nonferrous alloys and their composites
  • solidification
  • casting
  • metallurgical and manufacturing processes
  • microstructure development
  • defect formation

Published Papers (3 papers)

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Research

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32 pages, 12635 KiB  
Article
Solidification Simulation of Al-Si Alloys with Dendrite Tip Undercooling
by Hongda Wang, Mohamed S. Hamed and Sumanth Shankar
Metals 2022, 12(4), 608; https://doi.org/10.3390/met12040608 - 31 Mar 2022
Viewed by 1804
Abstract
A novel solution approach is proposed for the numerical simulation of the solidification process of binary Al-Si hypoeutectic alloys during upward and downward solidification modes. Undercooling is always observed during solidification, but the phenomenon could not be considered in the present-day numerical solution. [...] Read more.
A novel solution approach is proposed for the numerical simulation of the solidification process of binary Al-Si hypoeutectic alloys during upward and downward solidification modes. Undercooling is always observed during solidification, but the phenomenon could not be considered in the present-day numerical solution. In this approach, the temperature distribution in the mushy zone was used to define the fraction of solid, which enabled the evaluation of the effect of dendrite tip undercooling on the characteristics of the binary alloy solidification. The present numerical algorithm was found to significantly reduce the computation time. Transient temperature distribution and solidification time from the numerical analysis, with consideration of natural convection due to temperature and concentration gradients, have been successfully simulated and validated with experiment results. Numerical results with consideration of dendrite tip undercooling have better agreement with experimental results. The effect of dendrite tip undercooling on the fluid flow (velocity profile), G, R and λ1 for both upward and downward solidification modes of Al-Si alloys have been investigated and discussed. Consideration of undercooling was found to increase G and reduce R in both solidification modes. During downward solidification, considering undercooling significantly increased flow velocity and decreased λ1. The primary dendrite arm spacing could be validated with results from uni-directional solidification experiments only when dendrite tip undercooling was considered. Full article
(This article belongs to the Special Issue Modeling and Simulation of Solidification and Casting)
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11 pages, 3321 KiB  
Article
The Microstructure in an Al–Ti Alloy Melt: The Wulff Cluster Model from a Partial Structure Factor
by Xiaohang Lin, Lin Song, Anchen Shao, Minghao Hua, Hui Li and Xuelei Tian
Metals 2021, 11(11), 1799; https://doi.org/10.3390/met11111799 - 9 Nov 2021
Cited by 1 | Viewed by 1834
Abstract
In the present work, the Wulff cluster model—which has been proven to successfully describe pure metals, homogeneous alloys, and eutectic alloys—has been extended to complex binary Al80Ti20 alloys, containing intermetallic compounds. In our model, the most probable structure in metallic [...] Read more.
In the present work, the Wulff cluster model—which has been proven to successfully describe pure metals, homogeneous alloys, and eutectic alloys—has been extended to complex binary Al80Ti20 alloys, containing intermetallic compounds. In our model, the most probable structure in metallic melts should have the shape determined by Wulff construction within the crystal structure inside, and the cluster’s size could be measured by pair distribution function. For Al80Ti20 binary alloy, three different types of clusters (Al cluster, Al3Ti cluster, and Ti cluster) were proposed. Their contributions in XRD results are investigated by a comparison with the partial XRD pattern. Ti–Ti and Al–Ti partial structural factors are completely contributed by a pure Ti cluster and an Al3Ti cluster, respectively. Al–Al partial structural factor is contributed not only by a pure Al cluster but is also related to part of the Al3Ti cluster. The simulated XRD curve shows a good agreement with the experimental partial I(θ), including the peak position, width, and relative intensity. Full article
(This article belongs to the Special Issue Modeling and Simulation of Solidification and Casting)
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Review

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25 pages, 6748 KiB  
Review
Al Alloys and Casting Processes for Induction Motor Applications in Battery-Powered Electric Vehicles: A Review
by Yuxian Li, Anita Hu, Yintian Fu, Sufeng Liu, Wutian Shen, Henry Hu and Xueyuan Nie
Metals 2022, 12(2), 216; https://doi.org/10.3390/met12020216 - 24 Jan 2022
Cited by 16 | Viewed by 5732
Abstract
With the rapid expansion of battery-powered electric vehicles (BEVs) in the automotive industry, research interest in lightweight Al alloys as well as their casting processes and applications has increased considerably. The substitution of castable aluminum alloys with superior strengths and electrical conductivity for [...] Read more.
With the rapid expansion of battery-powered electric vehicles (BEVs) in the automotive industry, research interest in lightweight Al alloys as well as their casting processes and applications has increased considerably. The substitution of castable aluminum alloys with superior strengths and electrical conductivity for copper reduces the weight and size of electric induction motors, and improves the energy efficiency and driving range of the BEVs. The present article was intended to give a general introduction into the common cast Al aluminum alloys and their relevant processes, as well as to motivate the development of high strength and conductive Al alloys for the practical realization of Al applications in the motors of the BEVs. A number of cast alloy systems containing Cu, Si, Ni, Mg, Fe, and Ti were evaluated, in comparison to nanostructured wrought Al alloys. The conventional casting processes suitable for Al alloys, high pressure die casting, squeeze casting, and sand casting were described. Strengthening mechanisms including solid solution strengthening, precipitation strengthening, dislocation accumulation strengthening, and grain boundary strengthening were presented. The phenomenon of electrical conduction for Al alloys was outlined. The mechanical properties and electrical properties of the recently developed Al alloys for casting and deformation processes were comprehensively listed and critically reviewed in association with microstructural characteristics. Full article
(This article belongs to the Special Issue Modeling and Simulation of Solidification and Casting)
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