Temperature drop during casting verified

In simulating the casting process, it is important that input data is accurate. Swerea has measured and confirmed the temperature of molten metal during die casting. The results have enabled correct and more reliable simulations.

The foundry industry is increasingly using simulations to study and further develop the casting process. This saves time and expense because it can decrease actual physical testing. To attain correct results however, the input data must be accurate.

Data verified for simulations 

The metal’s temperature is an important parameter in simulations. The Association of Swedish Foundries and Swerea have therefore measured and verified the temperature of molten aluminium during the initial phase of die casting. The results of the measurements are used as input data in the simulations.

Die casting involves forcing molten metal into a mold cavity where it subsequently solidifies. The molten metal is transported with a pot from a nearby furnace and poured into the casting machine’s chamber. There is a piston in the chamber that then forces the molten metal into the die.

100 degrees drop in temperature

 Although the distance between the furnace and chamber is only about one metre, the temperature of the molten metal drops by 100 degrees. This was previously assumed but has now been confirmed. Swerea has measured the temperature of the molten metal in the chamber and been able to confirm the temperature drop.

“We’ve always known that we have a temperature drop when filling metal, but not that it was that much lower,” says Håkan Fransson, CEO at NovaCast Systems AB.“The project has enabled more realistic simulations of casting errors caused by low temperatures.”