Simulation of cooling channel rheocasting process of A356 aluminum alloy using three-phase volume averaging model

The cooling channel process is a rheocasting method by which the prematerial with globular microstructure can be produced to fit the thixocasting process. A three-phase model based on volume averaging approach is proposed to simulate the cooling channel process of A356 aluminum alloy. The three phases are liquid, solid and air respectively and treated as separated and interacting continua, sharing a single pressure field. The mass, momentum, and enthalpy transport equations for each phase are solved. The developed model can predict the evolution of liquid, solid and air fraction as well as the distribution of grain density and grain size. The effect of pouring temperature on the grain density, grain size and solid fraction is analyzed in detail.