Caratterizzazione e simulazione di processi di colata in sabbia di ghise sferoidali

This work focuses on a numerical-experimental characterization of casting processes of sand ductile iron. Initially, a deep phase of literary review has been carried out in order to completely understand the effects of the process parameters (alloy chemical composition, melt treatment and cooling rates) on defects, microstructures and mechanical properties of castings and to evaluate the state of the art of the numerical instruments of simulation of solidification dynamics and microstructure prediction. Experimental casting equipments have been designed and developed in order to measure and control the cooling rates and to validate instrument of numerical simulation and microstructure prediction. Moreover, specific methods and instruments have been designed, tested and used in order to measure and analyze temperatures inside the central parts of castings, also in case of heavy sections. Metallographic samples of material, obtained with different conditions, have been studied by means of optical analysis in order to evaluate microstructural features gradient, verifying the effect of the considered process parameters on microstructures parameters such as dimension and distribution of graphite nodules and content of ferrite and pearlite. In heavy section castings, a strong influence of macrosegregation and convective phenomena on microstructures and defects was found. The main part of the activities focused on numerical simulation FEM of the performed casting processes. The measured data of temperatures and microstructures have been used for the validation and optimization of the numerical simulations and of the analytical-empirical models for microstructure prediction in a wide range of process condition. The use of reliable instruments for simulation of casting process, with the adding of the implementation of experimental correlation microstructures-mechanical properties, allows for the evaluation of final properties and defects of castings, giving an important help in the optimization of the final product and its relative production process.