Improving Casting Simulation Accuracy Through Thermal Analysis of Aluminum Alloys

Cooling curve analysis enables accurate determination of aluminum alloy solidification parameters while capturing important non-equilibrium phenomena that are difficult to resolve using thermodynamic models alone. Modern casting simulation tools such as MAGMASOFT and ProCAST provide advanced capabilities, including user-defined material databases and microstructure models, but their predictive accuracy depends strongly on the quality of alloy-specific input data. In particular, the effects of trace element variations and chemical modification treatments, such as strontium-induced depression of the Al–Si eutectic temperature, are not always quantitatively represented in generic databases. This study demonstrates that thermal analysis provides experimentally based solidification data under controlled cooling conditions representative of foundry practice. Cooling curve analysis directly records undercooling, recalescence, and modification-induced temperature shifts, including eutectic temperature changes of ~10 °C after strontium treatment, which significantly influence solidification kinetics and defect formation. A short industrial thermal analysis test enables the extraction of key parameters, including liquidus, eutectic, coherency, rigidity, and solidus temperatures; fraction-solid evolution; and latent heat release. When integrated into casting simulation databases, these experimentally derived parameters support improved modeling of feeding behavior, shrinkage porosity risk, hot tearing tendency, and microstructure development. The proposed approach positions cooling curve analysis as a practical complementary tool for calibrating and enhancing simulation input data under real alloy and process conditions.