The 3rd edition of this popular textbook covers current topics in all areas of casting solidification. Partial differential equations and numerical analysis are used extensively throughout the text, with numerous calculation examples, to help the reader in achieving a working knowledge of computational solidification modeling. The features of this new edition include: • new chapters on semi-solid and metal matrix composites solidification • a significantly extended treatment of multiscale modeling of solidification and its applications to commercial alloys • a survey of new topics such as solidification of multicomponent alloys and molecular dynamic modeling • new theories, including a theory on oxide bi-films in the treatment of shrinkage problems • an in-depth treatment of the theoretical aspects of the solidification of the most important commercial alloys including steel, cast iron, aluminum-silicon eutectics, and superalloys • updated tables of material constants.

This collection encompasses the following four areas: (1) Solidification processing: theoretical and experimental investigations of solidification processes including castings solidification, directional solidification of alloys, electromagnetic stirring, ultrasonic cavitation, mechanical vibration, active cooling and heating, powder bed-electron beam melting additive manufacturing, etc. for processing of metals, polymers and composite materials; (2) Microstructure Evolution: theoretical and experimental studies related to microstructure evolution of materials including prediction of solidification-related defects and particle pushing/engulfment aspects; (3) Novel Casting and Molding Processes: modeling and experimental aspects including high pressure die casting, permanent casting, centrifugal casting, low pressure casting, 3D silica sand mold printing, etc.; and (4) Cast Iron: all aspects related to cast iron characterization, computational and analytical modeling, and processing.

We come to know about the world in two distinctive ways: by direct perception and by application of rational reasoning which, in its highest form, is mathematical thinking. The belief that the underlying order of the world can be expressed in mathematical form lies at the very heart of science. In other words, we only know what we can describe through mathematical models. Casting of metals has evolved first as witchcraft, to gradually become an art, then a technology, and only recently a science. Many of the processes used in metal casting are still empirical in nature, but many others are deep-rooted in mathematics. In whatever form, casting of metals is an activity fundamental to the very existence of our world, as we know it today. Foundry reports indicate that solidification modeling is not only a cost-effective investment but also a major technical asset. It helps foundries move into markets with more complcx and technically demanding work. The ability to predict internal soundness allows foundries to improve quality and deliveries, and provides the information required to make key manufacturing decisions based on accurate cost estimates before pattern construction even begins. The acceptance of computational modeling of solidification by the industry is a direct result of the gigantic strides made by solidification science in the last two decades.

Stefanescu here attempts to describe solidification theory through the complex mathematical apparatus required for a fundamental treatment of the problem. The mathematics is however restricted to the elements essential to attain a working knowledge in the field. This is in line with the main goal of the book, which is to educate the reader in the fast moving area of computational modeling of solidification of castings. A special effort has been made to introduce the reader to the latest developments in solidification theory including, in this second edition, a new chapter on semi-solid casting.

Written by leading experts in their respective fields, Solidification and Casting provides a comprehensive review of topics fundamental to metallurgy and materials science as well as indicates recent trends. From an industrial perspective, the book begins with chapters on the casting techniques most commonly used in industry today. It then d

We come to know about the world in two distinctive ways: by direct perception and by application of rational reasoning which, in its highest form, is mathematical thinking. The belief that the underlying order of the world can be expressed in mathematical form lies at the very heart of science. In other words, we only know what we can describe through mathematical models. Casting of metals has evolved first as witchcraft, to gradually become an art, then a technology, and only recently a science. Many of the processes used in metal casting are still empirical in nature, but many others are deep-rooted in mathematics. In whatever form, casting of metals is an activity fundamental to the very existence of our world, as we know it today. Foundry reports indicate that solidification modeling is not only a cost-effective investment but also a major technical asset. It helps foundries move into markets with more complcx and technically demanding work. The ability to predict internal soundness allows foundries to improve quality and deliveries, and provides the information required to make key manufacturing decisions based on accurate cost estimates before pattern construction even begins. The acceptance of computational modeling of solidification by the industry is a direct result of the gigantic strides made by solidification science in the last two decades.

This text seeks to provide a comprehensive technical foundation and practical examples for casting process modelling technology. It highlights fundamental theory for solidification and useful applications for industrial production. It also details shape and ingot castings, semi-solid metalworking, and spray forming.