Defect Minimisation in Vacuum-Assisted Plaster Mould Investment Casting Through Simulation of High-Value Aluminium Alloy Components

VacuumVacuum-assisted plaster mould investment castingInvestment casting is one of the best available processes to manufacture ultra-high complexity castingsCasting for the aerospace and defence sectors. In light of the emerging cross-sectoral manufacturing industry digitalisation, process simulationProcess simulation appears as a very important tool to improve castingCasting yield, reduceReduce metallurgical scrap, and reduceReduce lead time to new product introduction. Considering the unique aspects and the level of customisation of the process system, this work will present a Computational Fluid DynamicsComputational Fluid Dynamics (CFD)-based simulationSimulation tool with bespoke settings (that include thermophysical properties). Optimal fill and solidificationSolidification parameters are identified for a representative geometry able to describe a variety of very complex, high-value aluminium alloyAluminium alloys components through an iterative process.