PSI - Issue 79

Kazem Reza Kashyzadeh et al. / Procedia Structural Integrity 79 (2026) 65–72

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(a) Max: 1270 ℃ (c) Max: 1165.02 ℃ Fig. 4. Temperature distribution in various casting scenarios including: (a) scenarios No. 1, (b) scenarios No. 2, and (c) scenarios No. 3 3.2. Filling and Solidification Defects The analysis of cold shuts, a critical defect caused by the premature meeting and solidification of two metal streams, provided a decisive differentiator. Both scenarios 1 & 2 exhibited high cold shut values (105.10 and 106.95, respectively), predicting a high likelihood of this defect forming in the final casting. Remarkably, scenario 3 demonstrated a complete absence of cold shuts (value of 0), confirming that the molten metal fills the mold cavity completely and cohesively before solidification begins. This result directly supports the superiority of the gating design in scenario No.3 for ensuring a sound casting. The solid fraction analysis further corroborates this finding. Analysis 3 achieved a maximum solid fraction of 1, indicating complete and uniform solidification throughout the casting. Analysis 2, with a maximum solid fraction of 0.6, and Analysis 1, with only 0.1, suggest incomplete solidification or isolated liquid pockets, which can lead to shrinkage porosity and inhomogeneous mechanical properties. (b) Max: 1164.41 ℃

(a) Max: 1.84 m/s

(b) Max: 2.03 m/s

(c) Max: 1.23 m/s

Fig. 5. Mold erosion as the simulation results of various casting scenarios including: (a) scenarios No. 1, (b) scenarios No. 2, and (c) scenarios No. 3.

3.3. Mold Erosion and Process Stability The velocity of the molten metal as it enters the mold cavity is a key factor in mold erosion. From Figure 5, scenario No. 2 caused to the highest velocity magnitude of 2.03 m/s, which poses a remarkable risk of eroding the green sand mold, leading to sand inclusions and surface defects on the casting. Moreover, the simulation results of scenario No.1