Modeling and simulation of semisolid casting

Processing of metal alloys in their mushy state represents a new trend in metal processing. The process produces components with low porosity, high crack resistance, and superior mechanical properties. However, its implementation to industrial applications is hampered by technical problems due to the complex theology of the material. The material behaves differently under slow and rapid transients and its response is time-dependent. In the present study, the thixotropic behavior of semisolid slurries is modeled using conservation equations and the Herschel-Bulkley fluid model. The model is implemented into a computer code to predict die filling. Results show that the final quality of the products depends on the processing conditions and the geometry of the die.