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One way of reducing the CO2 footprint for titanium alloysTitanium alloys can be by the innovative re-use of machining by-products (swarf). This paper will present modeling and simulationModeling and simulation for micro-sized casting in Ti-6Al-4V (Ti64) swarf, with the ultimate aim of the development of continuous castingContinuous casting applications. Finite Element (FE) modeling is employed to predict thermomechanical behaviour enabling optimisation of heat transfer coefficients for enhanced process controlProcess control. Computational Fluid Dynamics (CFD) simulationSimulation is used to simulate melt flow within a micro-scale crucible to ensure reliable molten metal delivery. Using simulationSimulation tools enables rapid design iteration and processProcess tuning without extensive trial-and-error experimentation. This work could contribute to circular economy practices and reinforces the role of digital twinsDigital twin in advancing net zeroNet zero manufacturing goals in metal manufacturing processesProcess.

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Modeling and Simulation Strategies of Micro-casting from Titanium (Ti-6Al-4V) Swarf

  • 会议论文

  • 发表日期：

    2026年

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  • J. P. Arul Mozhi Varman,
  • James Wainwright,
  • Wojciech Suder,
  • Tharmalingam Sivarupan,
  • Konstantinos Georgarakis,
  • Konstantinos Salonitis,
  • Mark Jolly,
  • Stewart Williams

摘要

One way of reducing the CO2 footprint for titanium alloysTitanium alloys can be by the innovative re-use of machining by-products (swarf). This paper will present modeling and simulationModeling and simulation for micro-sized casting in Ti-6Al-4V (Ti64) swarf, with the ultimate aim of the development of continuous castingContinuous casting applications. Finite Element (FE) modeling is employed to predict thermomechanical behaviour enabling optimisation of heat transfer coefficients for enhanced process controlProcess control. Computational Fluid Dynamics (CFD) simulationSimulation is used to simulate melt flow within a micro-scale crucible to ensure reliable molten metal delivery. Using simulationSimulation tools enables rapid design iteration and processProcess tuning without extensive trial-and-error experimentation. This work could contribute to circular economy practices and reinforces the role of digital twinsDigital twin in advancing net zeroNet zero manufacturing goals in metal manufacturing processesProcess.