J. Mater. Sci. Technol. ›› 2020, Vol. 49: 91-105.DOI: 10.1016/j.jmst.2020.02.028

• Research Article • Previous Articles     Next Articles

Predicting gas and shrinkage porosity in solidification microstructure: A coupled three-dimensional cellular automaton model

Cheng Gua, Colin D. Ridgewaya, Emre Cinkilica, Yan Lua, Alan A. Luoa,*()   

  1. a Department of Materials Science and Engineering, The Ohio State University, Columbus, OH 43210, USA
    b Department of Integrated Systems Engineering, The Ohio State University, Columbus, OH 43210, USA
  • Received:2019-11-23 Revised:2020-01-10 Accepted:2020-01-20 Published:2020-07-15 Online:2020-07-17
  • Contact: Alan A. Luo


Porosity formation during solidification of aluminum-based alloys, due to hydrogen gas and alloy shrinkage, has been a major issue adversely affecting the performance of solidification products such as castings, welds or additively manufactured components. A three-dimensional cellular automaton (CA) model has been developed, for the first time, to couple the predictions of hydrogen-induced gas porosity and shrinkage porosity during solidification microstructure evolution of a binary Al-Si alloy. The CA simulation results are validated under various cooling rates by porosity measurements in an experimental wedge die casting using X-ray micro computed tomography (XMCT) technique. This validated porosity moel provides a critical link in integrated computation materials engineering (ICME) design and manufacturing of solidification products.

Key words: Solidification, Cellular automaton, Microstructure simulation, Microporosity evolution