Modelling of Microstructure, Mechanical Properties and Structural Performance in Thin Walled Ductile Cast Iron

Ductile cast iron has good mechanical properties and low production cost and is therefore widely used as a construction material. Cast parts in ductile iron can however be improved further by optimisation with numerical modelling. This not only involves the casting process itself but also the subsequent mechanical performance during service. The casting process has a large influence on the finale mechanical properties and the numerical modelling of the solidification of ductile iron is therefore a key factor in the entire optimisation linking the process and the performance of the part.
Solidification of ductile cast iron is very complex involving many different factors such as properties and chemistry of the melt and the heat flow from the casting into the mould. Concerning the heat flow an important factor is the thermal resistance between the casting and the mould, normally described by the heat transfer coefficient (HTC). The knowledge about the HTC is however very little, especially concerning thin walled castings.
The aim of this project is to investigate the heat transfer from casting to mould experimental, with emphasis on the HTC. The results from the experimental work will be incorporated in an advanced numerical model of solidification of ductile cast. The output of the solidification simulation will be mechanical properties which can be used as input for the structural mechanical simulation of the casting part in the applied function.