Cast Iron

The full picture: Iron Casting Simulation

Casting process insight and understanding can be calculated in advance. By providing transparency and distinguishing between cause and effect, simulation creates the foundation for making the right decisions. Predictable casting quality strengthens your collaboration with customers and has a lasting effect on their trust in you.

In order to produce iron castings with optimized quality while minimizing production costs, foundry engineers have to master their processes without creating numerous sample castings. Casting process simulation provides this knowledge. Simulation creates the foundation for a secure layout of a suitable gating and risering system, it helps to optimize metallurgy and melting practice, and offers in-depth predictions of microstructure and casting properties. In this way, casting process simulation minimizes production risks and helps realize the potential of cast iron materials in economical and robust manufacturing processes.

Local nodularity of graphite for a CGI crankcase

For iron castings, understanding and optimizing processes through simulation comprises:

  • Realistic and detailed mapping of all process steps

  • Faster and more robust layout of ingates, runner dimensions, venting, feeders and chills

  • Reduced manufacturing risks by considering the metallurgical treatment and composition of the melt

  • Optimization of the filling process to provide a fast and controlled flow

  • Reduction of quality costs by avoiding casting defects that arise from misruns, dross and slag entrainment, gas porosity, and shrinkage

  • Reliable decisions through the quantitative prediction of component microstructure and properties

Influence of different Si contents on the amount of white iron in a chill

MAGMA, MAGMAiron and other material- and task-specific modules offer extensive possibilities to simulate iron casting processes in a realistic and reliable way. Among these are:

  • Consideration of the actual melt composition, melt treatment and inoculation

  • Utilization of kinetic models and micromodeling throughout the entire process for accurate shrinkage prediction based on the local solidification path and phases formed

  • Consideration of mold strength and its impact on shrinkage defects

  • Prediction of local microstructures and mechanical properties for gray, ductile and compacted graphite iron

  • Prediction of mold erosion, sand burn-on/penetration and tracking of sand inclusions

  • Detailed capabilities and data bases for vertically parted molding

  • Residual stresses and distortions in castings during solidification after shake-out, gate and riser removal during cooling and subsequent processing

  • Evaluation of stresses and distortion of the casting during solidification, shake-out, after removal of the gating and risering, as well as during subsequent cooling and machining process

  • Stress relief and distortion during heat treatment

Local pearlite distribution for GJS-500