Defects your Casting Simulation tool will never show you

Every major HPDC part spends much time in the design phase. Casting simulations are the standard way to analyze castability.

Is there something wrong with that approach?

Are the simulation tools faulty?

The answer to both questions is simple – no! But there is more to real-world casting than the casting simulation shows. Let me give you an example.

If you want to determine whether metal fronts within the casting recombine, there are two factors you can look at. One is the temperature difference between these two melt fronts, and the other is the fraction solid of the melts. If the temperature difference is small, it is likely to recombine. The same is true if the fraction solid is below 45%.

I tell you, there is a third option that your simulation tool cannot show!

Simulation tools cannot predict the residue in the die from spraying in the die. Melt front picks up the release agent residue and transports it through the casting. The melt front with release agent residue always has a barrier in front. This barrier layer aggravates the recombination with other melt fronts. The result is visible in a tensile bar or a welding test. The tensile bar has low elongation as the load-bearing area is severely reduced. In the welding trial, the excess release agent will burn off and reduce the weld seam quality.

What is the message here?

Do your simulations and fine-tune every step of your casting process to get the best outcome. The casting process has more of these stumbling blocks.

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