Numerical Simulation and Experimental Validation of Fluidity of AlSi12CuNiMg Alloy using Multi Spiral Channel with Varying Thickness

The cast AlSi₁₂CuNiMg alloy finds broad applications in automotive components. The manufacture of defect-free castings, especially for long, thin-walled structures, requires an understanding of filling properties. The main aim of this investigation is to understand the fluidity of an AlSi₁₂CuNiMg alloy in a multi-spiral channel with varying thickness through the casting simulation and validate it through casting experimentation. Furthermore, the effect of pouring temperature and section thickness on fluidity was investigated, and an optical microscopy was carried out for microstructure observation. The results showed that the flow length (L) of the alloy increased with increasing pouring temperature (T) and decreased with a reduction in the section thickness. In order to predict the fluidity of AlSi₁₂CuNiMg alloy obtained from the spiral tests, mathematical models \( (L_\text{f} = - 705 + 1.044 T + 46.17 x\)) were developed based on the functional relationship between the fluidity and casting parameters by fitting the fluidity data. The simulation results show good agreement (91%) with the fluidity length obtained in the experimental study. The benchmark can also be used to develop the fluidity database of different alloys for thin sections.