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Aluminum shape castings have been increasingly used in critical structures that require more reliable and quantifiable performance. Mechanical properties of aluminum castings strongly depend upon multiscale microstructure and casting defects that are determined by alloy and particularly complex casting process. To produce high integrity aluminum castings, comprehensive through-process modeling is vital for process optimization and casting quality assurance as computer simulations enable a better understanding of the physical phenomena involved during mold filling and solidification. Process modelling also offers opportunities to uncover some quality issues and quantities that are difficult or impossible to measure experimentally. This talk will review the latest development in aluminum casting process modeling and discuss requirements needed for more accurate prediction.
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