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Numerical Simulation and Process Optimization of Sn-0.3Ag-0.7Cu Alloy Casting
Hao Zhou1, Yingwu Wang1,2, Jianghua He3
1Materials Genome Institute, School of Materials and Energy, Advanced Computing Center, Yunnan University, Kunming 650091, China.
Materials (Basel, Switzerland)
|January 10, 2026
Summary
Optimizing Sn-0.3Ag-0.7Cu (SAC0307) casting involves controlling pouring temperature and heat transfer. Finite element analysis identified optimal parameters to minimize porosity and enhance alloy quality.
Area of Science:
- Materials Science
- Metallurgy
- Computational Materials Science
Background:
- Solidification shrinkage and inadequate feeding cause porosity in Sn-0.3Ag-0.7Cu (SAC0307) castings, impacting quality.
- The casting process's opacity hinders understanding the link between parameters and defect formation.
- Science-based optimization of SAC0307 casting quality is challenging due to process complexity.
Purpose of the Study:
- To investigate the influence of pouring temperature (PCT) and interfacial heat transfer coefficient (HTC) on porosity formation in SAC0307 alloy casting.
- To elucidate the mechanisms governing solidification quality and defect formation using numerical simulations.
- To identify an optimal processing window for enhanced internal soundness of SAC0307 ingots.
Main Methods:
- Finite Element Method (FEM) simulations were employed to analyze the casting process.
- Systematic investigation of PCT (290-390 °C) and HTC (900-5000 W/(m²·K)) effects on porosity.
- Experimental validation using macro- and microstructural characterization of cast samples.
Main Results:
- Pouring temperature (PCT) has a non-monotonic effect on porosity by influencing solidification mode and microporosity accumulation.
- Interfacial heat transfer coefficient (HTC) critically determines porosity morphology by controlling solidification rate and mode.
- An optimal processing window was identified at 350 °C PCT and 3000 W/(m²·K) HTC, improving interdendritic feeding and ingot soundness.
Conclusions:
- Numerical simulation provides a reliable basis for optimizing SAC0307 casting processes.
- Understanding the interplay between PCT, HTC, and solidification is key to achieving high-quality castings.
- The study offers a scientific foundation for the industrial production of defect-free SAC0307 alloys.
