State-of-the-art tools allow the prediction of residual stresses and iron casting distortion quantitatively. Casting quality issues related to thermally driven stresses in castings are also gaining increasing attention. This allows the prediction of local structures, phases and ultimately the local mechanical properties of cast irons, to asses casting quality in the foundry but also to make use of this quantitative information during design of the casting. To be able to quantitatively predict these defects, solidification simulation had to be combined with density and mass transport calculations, in order to evaluate the impact of the solidification morphology on the feeding behavior as well as to consider alloy dependent feeding ranges.įor cast iron foundries, the use of casting process simulation has become an important instrument to predict the robustness and reliability of their processes, especially since the influence of alloying elements, melting practice and metallurgy need to be considered to quantify the special shrinkage and solidification behavior of cast iron. Therefore, it is not enough to base the prediction of shrinkage defects solely on hot spots derived from temperature fields.
#MAGMASOFT CRACK AND DISTORTION FREE#
Depending on the alloy poured, different feeding behaviors and self-feeding capabilities need to be considered to provide a defect free casting. The support of the feeding related layout of the casting is still one of the most important duties for casting process simulation. New products such as wind turbines have opened new markets for an entire suite of highly reliable ductile iron cast components.ĭuring the last 20 years, casting process simulation has developed from predicting hot spots and solidification to an integral assessment tool for foundries for the entire manufacturing route of castings. The mechanical engineering industry has recognized the value in substituting forged or welded structures with stiff and light-weight cast iron castings. Abstract: High strength compacted graphite iron (CGI) or alloyed cast iron components are substituting previously used non-ferrous castings in automotive power train applications.