Use of numerical simulation in the production of porous-metal castings

Abstract

The article describes the design and optimization of the foundry production of porous metal. The formation of porous metal by infiltrating liquid metal into the mould cavity appears to be the fastest and most economical way. However, it is not possible to do it without proper production parameters. For this reason, a 3D model of a particular casting is first created in the Rhinoceros 4.0 software and then the entire production process is designed and optimized using the numerical simulation in the MAGMASOFT (R) 5.4 software. To create cavities in the casting, the use of sand cores is considered and the used unit bentonite mixture (UBM) becomes the mould material. With the simulations of pouring and solidification of the casting, the right conditions for the real production can be defined precisely; the time and financial costs connected with the production of non-conforming pieces can be saved. Thus, the aim is to ensure the production of sound castings that will find their use in the field of energy, specifically as heat exchangers.