Simulation-based prediction of micro-shrinkage porosity in aluminum casting: Fully-coupled numerical calculation vs. criteria functions

Micro-shrinkage porosity in aluminum casting is analysed by computer simulation using three criteria functions and a fully-coupled shrinkage porosity model. Three process simulations of different precision were executed as basis for the porosity prediction for investigation of the impact of simulation precision on porosity prediction. To validate the simulation predictions, three identical blocks were cast in a special experimental setup. Chill plates enforce shrinkage porosity, which was analyzed using computer tomography. The results demonstrate that both precise numerical simulations and precise porosity models are needed for reliable porosity prediction.