Numerical simulation of drainage and solidification processes of foam aluminum alloy

A mathematical model for drainage and solidification processes of foam aluminum alloy fabricated by gas injection into melt is presented based on the coupling of the foam drainage equation and the energy equation.The time evolution and spatial distribution of the aluminum alloy volume fraction and temperature during the solidification process are numerically predicted.Effects of relevant parameters,such as viscosity,surface tension and gravity acceleration,are discussed.Computational results show that foam drainage and solidification are two closely coupled and interactive processes,solidification time and volume fraction distribution after solidification have direct effect on melt foam drainage,and that the melt properties have significant influences on the solidification time and foam porosity.