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Now that the true defect had been identified, Custom Casting’s engineering department reduced the binder content of the sand, which yielded a slight improvement in the defect severity. The match of the real areas of gas defects of the sample casting with the simulation results showed a good correlation. The evaluation of the solidification progress shows that the defect prone region of the casting takes 140 seconds, after filling, to completely form a skin. We are delivering highest quality casting products with ultra-fast lead time to support customers who need complex shape casting within limited time frame.
#Complex casting magmasoft skin
The Fraction Solid results were used to identify the locations of the casting that formed a skin last and thus identified the entry point of the gas into the casting and the amount of time it was able to do so. Kimura Foundry Group is the leader in the field of 3D sand printing technology based on a long history as cast iron foundry with the world largest numbers of 3D sand printers. The second condition that must exist for core gas related porosity is an entry point for the gas to get into the casting. This and the evaluation of a sectioned core with uncured binder reveal that the core possesses all the required conditions to produce gas. A comparison of the core temperature at the start of the filling cycle with the core temperature at the end of the cycle showed that the cores are severely overheated. In order for the core to emit a gas there must be uncured binder in the core/mold, and these core/mold materials must reach high temperatures. However, the conditions that cause off-gassing of cores and their migration into the casting are accounted for by MAGMASOFT®. They were able to easily determine that the cores were reaching temperatures that promoted off-gassing. The challenge in addressing this defect, and thus resolving it, is that MAGMASOFT® does not directly calculate the evolution of gas from core and mold binders at this time. With the use of MAGMASOFT, Custom Castings was able to resolve a complex casting issue in a short amount of time. This meant that the casting defect was not shrinkage porosity after all, but that there was a condition in the process that was not being captured - core gas. The simulation inputs were all double-checked, all the process parameters were modified to the extremes of the possible, and yet the simulated defects varied only slightly. Large porous voids were detected in sample castings, despite the simulation results not showing any. (73 kg) part that had been previously produced as a gravity sand casting by another vendor. Substantiated by casting simulation results, they were able to acquire a 160 lb. Custom Castings has been using MAGMASOFT® for about one year to improve their casting quality and reduce sampling times.