Aston University Scientists Set to Advance Liquid Metal Casting with Innovative Mathematical Model

A new project at Aston University has been set up to develop a mathematical model to improve liquid metal casting.

The method will be used to help prevent lightweight aluminium alloys corroding – or oxidating – very quickly when first exposed to air. A better knowledge of this could improve the emerging processes related to 3D printing and additive manufacturing of light metals.

Within the transportation sector, steel is gradually being replaced by lighter alloys. Although they don’t rust like steel does, they oxidise very quickly when first exposed to external ambient conditions which affects their quality and lifespan.

Dr Paul Griffiths, senior lecturer in applied mathematics, will be conducting a 12-month project which will focus on the thin oxide films that develop on alloys which affect the casting process.

He has been awarded £80,000 from the Engineering and Physical Sciences Research Council (EPSRC) for the study ‘Developing an accurate non-Newtonian surface rheology model’.

Dr Griffiths, who is based in the University’s College of Engineering and Physical Sciences, said: “The aim of this investigation is to develop a mathematical model that accurately captures the two-way coupling between a liquid metal flow and the oxide layer above, with the latter behaving as a non-Newtonian liquid/gas interface.

“The objective of this project is to describe both the surface characteristics – velocity and shear profiles – as well as the important effects of surface curvature.

“The benefit of a more appropriate mechanical model for the oxidised surface of a melted metal flow would lead to a better understanding of the encapsulation process which affects the alloy.”

The research is twinned with a project partner in Grenoble, France.