Computer Modeling and Experimental Verification of Mold Filling in Counter-Gravity Lost Foam Casting Process

A dynamics of the molten metal-polymeric foam interface has been experimentally observed in “window counter-gravity lost foam casting” of standard GM plates. The observations allowed revealing the effect of the pyrolisis of polymeric foam material on molten metal propagation velocity. FLOW-3D software (Flow Science, Inc.) has been used to simulate liquid metal filling dynamics and the molten metal-polymeric foam interface velocity in foam plates. The effect of the degradation gaseous products on the molten metal-polymeric foam interface velocity was taken into consideration through specially written sub-routing program. The results of the simulations are compared with the experimental data obtained in this study.