Numerical Method for Calculation of Complete Casting Processes—Part II: Validation and Application

Abstract

In this article, the numerical method proposed in Part I is validated by applying it to relatively simple validation test cases with phase change as well as to real-life problems. First, the results of the 1-D calculations are compared with the analytical solutions for the Stefan problem with mushy zone. Then, the 2-D and 3-D calculations of the Bridgman crystal growth are compared with available experimental results. The ability to predict the residual stresses is demonstrated on an academic 2-D example. Finally, the results of calculation for two real-life industrial cases, injection casting and solidification of a multicomponent metal drill head, are presented and discussed.