Thermal stress analysis of a directionally solidified Al–1 wt%Ni alloy casting

As the development of thermal stresses is closely related to the cooling history of castings, it is essential to consider the thermal evolution from the molten state up to the solid condition at the room temperature. This work develops a thermal analysis solution applying the ANSYS software (ANSYS Inc., Southpointe, PA, USA). As a result, an integrated system of thermal stress analysis during the solidification process was developed. A solidification experiment was carried out in order to directionally solidify an Al–1 wt%Ni hypoeutectic alloy casting under upward unsteady-state heat flow conditions. The experimental cooling curves were compared with the temperature fields provided by ANSYS, and a good agreement has been observed. The thermal stresses were determined in the solid zone of the directionally solidified casting.