Optimized Fluid Flow Pattern for Automotive Lightweight Component Castings

Casting defects such as gas porosity, shrinkage, poor-fill and blistering are related to the filling pattern and flow control in Al and Mg die-casting. It is not clearly understood how atomized and turbulent flow affects the filling patterns and hence casting defects. Significant improvements in casting quality could be achieved with a better understanding of the basic morphology of atomized and turbulent flow and their relationships to the Reynolds number and J number. This paper will explore the relationship between atomized and turbulent flow in Al and Mg die castings and the relationship of wakes produced by obstacles in the flow path and casting defects.