Scope and Objectives

Development of an Open Source Solidification/Melting Simulation Platform - OpenSol, for simulating solidification based processes with a capability tp predict macroscopic segregation, bulk flow and shrinkage in various casting processes and multi-component alloy systems. Ability of OpenSol to link with thermodynamic models and lower length scale models, if needed. Validation of the OpenSol platform with the existing numerical and experimental data as well as with proposed in-house experiments. Customization of OpenSol for various solidification processes such as shape casting, continuous casting, arc welding, and crystal growth processes. Organization of training and demonstration of software to all stakeholders.

Deliverables

Open source solidification software (OpenSol) wth proper graphics user interface (GUI) for scientific prediction of solidification of multi-component alloys with documentation. Customized software for shape casting, arc welding and crystal growth.

Videos

Scientific Output

The proposed software Open sol will be the first major solidification software on an open software platform. It will have an interactive user interface that can cater to the requirements of foundry practitioners, engineers and scientists working on casting and solidification simulations. It will have controlled benchmark laboratory experiments data as validation tool. It will have capability to handle Al, steel and multi-component alloys. Further, training and demonstration of software will be provided with provision of bench marking the numerical test cases (applications). It will have flexibility to link with thermodynamic models and lower length scale (macro) models. Numerical simulation using the models developed can be applied to industrial products. It is expected that mechanical property prediction models in casting and welding utilizing micro-structure and local temperature data (based on empirical relationships) will benefit from this software.

Results and outcome till date

The following modules of two-dimensional flow are completed and some of the works on 3D flow are completed. The design work of in-house solidification experiments is almost complete. Experiments on melting will start once the PIV is installed.
(i) Forced convection
(ii) Turbulent convection
(iii) Free convection, multi-component species transport
(iv) Melting, solidification
(v) Macro-segregation
(vi) Porous media Images Attached

Societal benefit and impact anticipated

Indigenously developed open source solidification software will be accessible to strategic sectors of the country. The developed software will be a low cost and will be available to Indian industries. It is also made available for teaching so that students can have enhance their knowledge on the processes involving solidification and melting. Interactive graphics users interface (GUI) will make the software popular among the users as it can be used without going for the details of the code.

Next steps

Advanced realistic micro-segregation models with back diffusion. Experimental studies on transparent metals analogues. Data of temperature, mushy zone, velocity field, etc. will be generated which will be used for validating the solvers. Grain motion module along with integration of various microscopic phenomena. Free surface evolution module (application areas: mold filling, Marangoni convection in welding). Conjugate heat transfer to account for heat transfer in solid and fluid simultaneously. Modules to link thermodynamic database to solidification process. Demonstration: simpler plate type lab-scale casting, 3D complex shaped casting, Mold filling, Butt welding. Development of Graphics User Interface (GUI) for selection and formulation of the processes.

Publications and reports

Writing of few papers are in progress.

Patents

NIL

Scholars and Project Staff

Alok Kumar, PhD Student Qadir Hussain, PhD Student (On Semester Leave) Menaka A Ray, PhD Student (On Semester Leave) Zahid Ali Ansari, M. Tech (completed) Vishwajit Kumar, M. Tech (completed) Rahul Gangwar, M. Tech (completed) Rakesh Juyal, M. Tech Anup Singh, Project Associate

Challenges faced

MoU between the industries and the educational institutes could not be signed till date because of the reasons beyond the control of PI and PI institute. Consequently, the money could not be transferred to the institutes which is being reflected in the form of poor utilization of fund. Shortage of suitable manpower is hindering the developmental work which consequently being reflected in the budget.

Other information

MoU between the industries and the educational institutes could not be signed till date because of the reasons beyond the control of PI and PI institute. Consequently, the money could not be transferred to the institutes which is being reflected in the form of poor utilization of fund. Shortage of suitable manpower is hindering the developmental work which consequently being reflected in the budget.