Loch Ness - Mapping of invisible flows- Advanced simulation and sensoring for future HPDC

Purpose and goal

The goal in LochNess is to map and document mold filling during high pressure die casting. The purpose is to increase understanding of the effects and phenomena that lead to defects, enabling higher precision in the digitalization of the casting process. Mapping is carried out experimentally in a casting machine with high speed camera and fiber optic sensors.

Expected effects and result

Casting simulation is used to predict the casting process, leading to improved quality and reduced risk of defects such as cracking and porosities. Measurements have shown that flow-related effects such as turbulence and oxides directly limit the material´s mechanical performance. In the project, an important step is taken to reveal how the turbulent flows that occur in large structural die castings behave, so that the simulation methodology can also be expanded to these components.

Planned approach and implementation

The project will identify tools that are suitable for high-speed filming and sensoring with fiber optic sensors. Project is run in two tracks; installation procedure for fiber optic sensors where the requirements of precision and durability are taken into account and then installed in test tools. In a parallel track, strategy for high-speed filming is developed where tool modification and machine compatibility are the focus. Trial casting takes place with a sensored and video-equipped tool.