SOLIDCast® aided optimization of manufacturing conditions of tension test specimens for copper alloy Cu-8%Sn (AS-CAST)

Abstract

Obtaining molten test bodies with minimum amount of defects is an important factor during the tensile mechanical testing of metallic materials; in this sense it is necessary to improve the manufacturing conditions of castings to obtain measurements with reliable results. This work shows the prediction of defects and the parameters’ optimization of the foundry models proposed by the ASTM B208-14 standard, by simulating the casting for a Cu8% Sn alloy using SOLIDWorks® and SOLIDCast®. The optimization results show that temperature, emptying time and turbulence of the liquid metal vary when compared to the proposed designs. The temperature of the liquid metal is homogeneous in the volume of the piece, always above the temperature of liquids during the filling of the mold. The flow lines show a reduction in the turbulence of the liquid metal, reducing the possibility of oxidation and gas entrapment. The simulations also showed that the feeder compensated the contractions and its dimensions remained constant, allowing to obtain a greater number of test bodies. The model plate was manufactured by means of 3D printing obtaining a model with high mechanical resistance and good surface finish. The molding was carried out in silica sand agglomerated with phenolic resin, later penetrating liquids were used in the melted part in the “as-cast” state to verify the health validating the results obtained in the simulations, evidencing that the software predicts the health of parts foundry, helping to reduce labor time and costs.