FLOW-3D CAST‘s defect tracking capabilities help casting engineers predict where surface oxide defects are most likely to occur from the filling process. Oxides form due to an exposed molten metal surface to air and can end up in the part in undesirable locations. The final location of the defects depends on the overall flow conditions, turbulent mixing, fluid jetting and impingement. FLOW-3D CAST accurately tracks these oxides and their final locations to help improve designs.

This FLOW-3D CAST filling simulation of a water pump shows the temperature distribution through a detailed filling pattern.

This FLOW-3D CAST filling simulation of an automotive component visualizes the oxide formation variable to understand where defects can become an issue in the filling process.

This FLOW-3D CAST filling simulation of a complex thin walled part shows the air entrainment variable to understand where defects can become an issue in the filling process. Visualization of air entrainment can be used to understand die venting, back-pressure, and areas of porosity.

This FLOW-3D CAST filling simulation of a complex thin walled part with salt cores shows the use of gate tracers to visualize rigging performance.

This is a simulation of an automotive flywheel or bell housing, showing velocity contours of an aluminum alloy during a fast shot of a high pressure die casting process. It is part of a design phase to evaluate different gating options. Shown here is a comparison of five gates, simulating filling from a runner below the parting line to accomplish an 80-millisecond casting fill. The left-hand simulation in the video shows gates pointed upward below the parting line, while the right-hand simulation shows gates at the same location, angled at 45 degrees. Learn more at www.flow3d.com/cast.