Developing a new 2D model for heat transfer and foam degradation in EPS lost foam casting (LFC) process

In this study, a 2D model is developed for heat transfer, foam degradation and gas diffusion at the interfaces of the liquid metal, foam pattern and gaseous gap in between, for EPS lost foam casting process. In this model based on mass and energy balance between gas and molten metal, radiation and conduction between foam and molten metal and convection between gas and molten metal are considered, both metal and foam surfaces are tracked and gap volume and pressure are calculated. A combination of energy balance and geometric correlations is used to define receding foam surface during mold filling. Gas flow in the gap is considered as wedge flow and Nusselt number for a laminar incompressible wedge flow is used for it. To apply our model to an example case, SOLA-VOF algorithm was used to simulate the flow of molten metal with free boundaries. Model results are compared with some data reported in the literature which show acceptable agreement. It is found that besides radiation in the gaseous area between foam and molten metal, conduction also plays an important role in foam degradation and control of molten metal velocity. This model can acceptably predict the effect of some parameters like foam density, coating permeability and foam degradation temperature.