Numerical Modeling of Die Filling of Semi-Solid A356 Aluminum Alloy

Computer base and simulation technique have been applied for modeling the semi-solid die filling and part of the solidification process of aluminum A356 alloy. A fairly simple one-phase theological model has been implemented into a fluid flow finite element software Procast, to solve the partial differential equations. This model is purely viscous nature and is implemented in the power law cut-off model of Procast. The constitutive parameters of this model were determined for a rheocast A356 alloy. Using these parameters and comparing the simulation results with experimental data showed good correlation with the model prediction. The designed die for rheocasting was applied for the production of a small propeller with thin section.