FLOW-3D Cast accurately predicts die erosion defects due to cavitation during filling in high pressure die casting. Metal pressure can drop several atmospheres below the metal vapor pressure in areas of very fast flow, possibly causing cavitation and erosion. A simple way to predict damage due to cavitation is to predict the likelihood of the cavitation, or the cavitation potential, without actually introducing cavitating bubbles into the flow. FLOW-3D Cast evaluates the cavitation potential by looking at the difference between the cavitation pressure and the local fluid pressure. The potential for cavitation and die erosion at the cell’s location is deemed to exist when this difference is large. The most reliable indications of possible die erosion are highly-localized “hot spots” — small areas with high values of this quantity.