Process Simulation Role in the Development of New Alloys Based on an Integrated Computational Materials Engineering Approach

To accelerate the introduction of new materials and components, the development of metal casting processes requires the teaming between different disciplines, as multi-physical phenomena have to be considered simultaneously for the process design and optimization for mechanical properties. The required models for physical phenomena as well as their validation status for metal casting are reviewed. The data on materials properties, model validation, and relevant microstructure for materials properties are highlighted. One vehicle to accelerate the development of new materials is through combined experimental-computational efforts. Integrated computational/experimental practices are reviewed; strengths and weaknesses are identified with respect to metal casting processes. Specifically, the examples are given for the knowledge base established at Oak Ridge National Laboratory and computer models for predicting casting defects and microstructure distribution in aluminum alloy components.