Simulation Based Fluidity and Solidification Analysis of Aluminium-Copper Sand Cast Alloy

Abstract

Aluminium-copper alloys are known for their very good strength at high temperature .Addition of copper improves the strength at high temperatures due to precipitation strengthening. Fluidity in casting is the major factor which affects the cast quality of the final components. Addition of Silicon with copper in Aluminium improves fluidity and finally quality of the cast components. But presence of Silicon adversely affects the strength at high temperature. In the present work cooling curve analysis of Al-Cu alloy (without Silicon) is done for different wt% of copper addition. The current study for Al-Cu alloy is based on sand casting method as it is one of the cost effective manufacturing method. Cooling curve obtained from the simulation results used to predict the fluidity, microstructure of the alloy when copper wt% is varied. Predicted microstructure and grain structure from the cooling curve goes well with the microstructure studied from shop floor casting .In the present work “Z-cast” casting simulation software is used for casting simulation. Among three different alloy composition studied aluminium with 8% copper gives the best results when compared on the basis of grain size .But fluidity analysis reveal poor fluidity for the alloy having 8 wt% of copper. The current analysis helps to study the optimum aluminium –copper alloy composition that can be used in high temperature applications.