Advanced Injector Geometry for Dual Alloy Casting: Design, Testing and Evaluation

The demand for components with tailored properties or functional graded materials with adjustable interfaces increases the challenges regarding the manufacturing process in gravity sand and die casting of aluminium. Based on the injector casting, a controlled process is being developed in which two liquid aluminium alloys are introduced sequentially. By adapting the injector outlet, an effort is made to achieve a deflection of the flow in a desired horizontal direction. Variations of a horizontal deflection at the injector outlet and their effects on the flow and mixing are analysed and validated using water models and corresponding CFD simulations.