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Dross is one of the most challenging quality issues in high integrity ductile iron castings. The formation of dross is linked to the applied metallurgy, metal treatment, process control and gating/rigging design. One of the primary concerns in this regard is entrainment of air into the melt during filling of the casting. Today, avoiding and controlling dross relies on the practical experience and process know-how of foundry experts. A quantitative understanding of the formation mechanisms or the prediction of final amounts and locations of dross in castings is not available. In this paper a computational model is developed for predicting the formation, motion and final location of dross inclusions during pouring of ductile iron castings. The focus is on the important mechanism of dross generation due to air entrainment during filling of the mold. The model predicts the local air entrainment rate as a function of the turbulent kinetic energy of the liquid metal and the normal velocity gradient of the metal at the liquid metal-air interface. The dross inclusions resulting from the exposure to the entrained air are transported with the melt flow under the combined influences of drag and buoyancy, and captured by the solidifying casting structure. The model is implemented in a commercial casting simulation software code. Ductile iron casting experiments are conducted to validate the model using castings having a variety of gating systems, section thicknesses, and surface orientations. Dross is measured by serial sectioning of the solidified castings. Good agreement between measured and predicted dross amounts and locations is obtained. The results reveal how gating system design affects dross formation. Clean ductile iron castings can be obtained by minimizing air entrainment during pouring. The present model allows foundries to evaluate different gating designs and pouring parameters before the first casting is poured. The paper also discusses open issues and practical challenges in quantifying the amounts of dross as a function of the entire processing route of a casting.

Modelling Approach and Challenges in Simulating Dross Formation in Ductile Iron Castings