Patent ID: 9652566
Date: 2017-05-16
CPC Classifications: G01M,G06F

Claim:
1. A method of simulating aluminum oxides defects in aluminum castings comprising: providing a casting mold and a mold filling approach for casting an aluminum melt; determining the free surface area for a plurality of particles of aluminum in the aluminum melt; storing the free surface area for each particle of aluminum; tracking the free surface area change during filling of the casting mold; calculating the total area of entrained or surface oxide films based on the free surface area change during filling of the casting mold in accordance with the mold filling approach; determining the total area of bifilms created, wherein the total area of bifilms are calculated by storing the area of contact between fluid fronts meeting at angles of more than 135 degrees for each of the plurality of particles and summing over all particle areas; determining the total area of cold shuts created, wherein the total area of cold shuts are calculated by storing the area of bifilms created at temperatures below the median temperature of a freezing range; determining a velocity of the aluminum melt at multiple locations; and optimizing the casting mold and mold filling approach to minimize the aluminum oxide defects based on one of the determined free surface area for a plurality of particles of aluminum in the aluminum melt, and determined total area of bifilms created, determined total area of cold shuts created, and determined velocity of the aluminum melt at multiple locations; wherein the velocity of the aluminum melt is determined using the algorithm wherein u