Thermo-mechanical analysis of investment casting ceramic shell: A case study

•Both thermal and mechanical aspects of casting process have been considered in the present work.•The modeling results have been validated with the experimentation results with a very close proximity.•The deformation in the ceramic shell increases with increase in inner mould temperature.•The maximu...

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Bibliographic Details
Published in:Measurement : journal of the International Measurement Confederation 2019-12, Vol.147, p.106805, Article 106805
Main Authors: Behera, Madan Mohan, Pattnaik, Sarojrani, Sutar, Mihir Kumar
Format: Article
Language:English
Subjects:
Aluminum base alloys
Casting
Casting defects
Ceramic mold casting
Ceramics
Computer simulation
Experimentation
Heat transfer coefficients
Internal pressure
Investment casting
Liquid metals
Literature reviews
Material properties
Mathematical models
Metals
Modeling
Silicon base alloys
Software
Solidification
Temperature
Thermal stress
Thermomechanical analysis
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Summary:•Both thermal and mechanical aspects of casting process have been considered in the present work.•The modeling results have been validated with the experimentation results with a very close proximity.•The deformation in the ceramic shell increases with increase in inner mould temperature.•The maximum deformation is observed around the circumference of the ceramic shell and in the upper regions of the sprue.•The stress distribution on the mould surface is highly concentrated at the base and fin region. In investment casting (IC) process, the mould is subjected to stress due to both internal pressure of the molten metal and the thermal stress generated due to the temperature variation across the mould boundary at the time of pouring and during solidification. The solidification pattern and solidification time have predominant effect on the material properties of the casting produced from this process. In the present work, an IC ceramic shell is used as mould for the numerical simulation of the thermal stresses generated and solidification process of Al-7%Si alloy inside it using COMSOL Multiphysics software. The effect of heat transfer coefficients between the casting and ambient air on the solidification pattern and solidification time have also been simulated. The results obtained from the simulation were found to be in good compliance with the data obtained from the experimentation and literature survey. Therefore, this modeling provides promising possibility for the predetermination of casting defects in mould as well as in casting.
ISSN:0263-2241
1873-412X
DOI:10.1016/j.measurement.2019.07.033