Simulation of Shrinkage/Voids Formation in Lead Casting and its Experimental Validation

In this research work a defect-free direct method of lead castings was developed. To achieve this, existing defects in the direct method of lead castings were investigated. This was developed by computing models and simulating the casting process to identify the source of defects and the optimum conditions for the direct method of casting lead. An improved model to the existing casting process was developed. The key parameters of the casting process were established through quantitative and qualitative data collection techniques including temperature sensors and defect analysis. The model was simulated using the key process parameters identified on commercial solidification software, ProCast, to establish the cause and effect of each parameter on the overall quality of lead casting. In this research work, solidification of lead has been carried out in different size of metallic mold to predict the formation of shrinkage during solidification. Theoretical results have been validated experimentally for a particular case of lead solidification. The simulated results were found in good agreement with experimental results. Voids appeared at the top and isolated area of castings for defect free direct method used in this study.