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An Available Technique for Preparation of New Cast MnCuNiFeZnAl Alloy with Superior Damping Capacity and High Service Temperature

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Numerical Simulation and Process Optimization of Sn-0.3Ag-0.7Cu Alloy Casting.

Hao Zhou¹, Yingwu Wang^1,2, 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.

Keywords:

Sn-0.3Ag-0.7Cu alloy finite element method heat transfer coefficient porosity pouring temperature

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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.