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The presence of non-metallic inclusions, such as aluminaAlumina, in aerospace aluminium alloyAluminium alloys castingsCasting significantly limits the potential mechanical propertiesMechanical properties. Building on previous simulationSimulation studies (TMS 2024) that focused on the melt flowrate, the current study explores optimised launder designs using strategically placed baffles to promote effective sedimentationSedimentation of these non-metallic inclusions. Utilising high-resolution CFDComputational Fluid Dynamics (CFD) simulationsSimulation in Flow3D, the influence of baffle angle (0°, 15°, 30°, and 45°), configuration (single/double), and placement (middle/near-inlet) on flow behaviour and inclusion settling efficiency has been evaluated. Baffles angled at 15° significantly reduce turbulence and create near-stagnation-velocityVelocity zones ideal for inclusion growth and sedimentationSedimentation; AlTiB master alloyMaster alloy promotes intermetallicIntermetallics growth on pre-existing aluminaAlumina bifilmsBifilm. Double baffle setups, one towards the launder inlet and another at the centre, outperformed single baffles in enhancing inclusion sedimentationSedimentation without disrupting flow continuity. The configuration redirects convective flow, increasing inclusion residence time and promoting downward migration.

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Baffle-Based Sedimentation Strategies for Inclusions in Launders of Aerospace Aluminium Casting: A Sustainable Approach

  • 会议论文

  • 发表日期：

    2026年

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  • Tharmalingam Sivarupan,
  • Arul Mozhi Varman Jayaraman Palanivel,
  • Konstantinos Georgarakis,
  • John Forde,
  • Joseph Rawding,
  • Ben Shaw,
  • Konstantinos Salonitis,
  • Mark Jolly

摘要

The presence of non-metallic inclusions, such as aluminaAlumina, in aerospace aluminium alloyAluminium alloys castingsCasting significantly limits the potential mechanical propertiesMechanical properties. Building on previous simulationSimulation studies (TMS 2024) that focused on the melt flowrate, the current study explores optimised launder designs using strategically placed baffles to promote effective sedimentationSedimentation of these non-metallic inclusions. Utilising high-resolution CFDComputational Fluid Dynamics (CFD) simulationsSimulation in Flow3D, the influence of baffle angle (0°, 15°, 30°, and 45°), configuration (single/double), and placement (middle/near-inlet) on flow behaviour and inclusion settling efficiency has been evaluated. Baffles angled at 15° significantly reduce turbulence and create near-stagnation-velocityVelocity zones ideal for inclusion growth and sedimentationSedimentation; AlTiB master alloyMaster alloy promotes intermetallicIntermetallics growth on pre-existing aluminaAlumina bifilmsBifilm. Double baffle setups, one towards the launder inlet and another at the centre, outperformed single baffles in enhancing inclusion sedimentationSedimentation without disrupting flow continuity. The configuration redirects convective flow, increasing inclusion residence time and promoting downward migration.