Predictive Modeling of Porosity Formation in Directionally Solidified AlSi10Mg Alloy: Effects of Temperature Gradient, Solidification Time, and Interface Velocity

Year 2025, Volume: 9 Issue: 4, 455 - 460, 31.12.2025

Selçuk Şirin , Adem Demir

https://doi.org/10.30939/ijastech..1768303

Abstract

Aluminum casting alloys are widely utilized today, particularly in the automotive sector, in line with the pursuit of designing lightweight and energy-efficient vehicles. This widespread application is attributed to their advantageous properties, such as low density, high corrosion resistance, high strength, and superior thermal and electrical conductivity. Porosity, which is one of the most common problems in the products produced by the casting method, renders the product unusable. Since directional solidification is unidirectional heat flow, the effects of solidification parameters, such as temperature gradient, solidification time, solid-liquid interface velocity, on porosity, can be investigated. In this study, the effects of the temperature gradient, solidification time, solid-liquid interface velocity parameters on pore formation were investigated in the one directionally solidified AlSi10Mg alloy at different solidification parameters. Density analysis and microscopic image analysis methods were used according to Archimedes' principle to measure porosity in the samples. When the results obtained are examined one by one, it is seen that the increase in temperature gradient decreases the porosity. However, it has been detected that porosity increases with increasing solid-liquid interface velocity and solidification time. A mathematical model was developed using regression analysis to predict porosity formation with R² = 0.857, showing good correlation between solidification parameters and porosity formation.

Keywords

aluminum , Directional Solidification , Mathematical Modelling , Porosity , Regression Analysis

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