Numerical simulation of liquid aluminum leakage in casting process

Abstract A model was built to simulate liquid aluminum leakage during the casting process, including transient trough flow, orifice outflow, and spread, to prevent the explosion. A comparison between the simulation data and the theoretical calculation results verifies that the model has remarkable adaptability and high accuracy. Although the height of liquid aluminum in the mixing furnace and outlet radius are changed, the molten aluminum will not leak during the casting process. The aluminum in the trough moves forward in a wave-like motion and causes a leakage. The spread of the leaked aluminum resembles a long strip on the ground. The leakage amount and spread area of liquid aluminum increase with increasing the height of liquid aluminum in the mixing furnace.