Correctly modeling the fluid flow and heat transfer during the filling of a mold with a molten metal, and the thermal-mechanical physics of solidification and cooldown is important in predicting the quality of a cast part. Determining the dynamics of the flow and the free surface shape during filling are essential in establishing the temperature gradients in the melt and in the mold. Correctly modeling the physics of volume change on solidification, shrinkage on cooling, and contact resistance across the part-mold interface directly affects the cooling rate and ultimately the final cast shape and stress state of the cast part. In this paper we describe our current research efforts on modeling fluid fill using the commercial code ProCAST by UES, and thermal-mechanical solidification modeling using the code CAST2D by LLNL.
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