View metal casting validations from customers around the world who use FLOW-3D CAST to improve their designs and manufacturing processes.

Ladle Pour

Optimizing your shot sleeve process is essential to ensuring quality parts. This comparison between FLOW-3D CAST’s simulation results and a real-world case highlights how using simulation can help engineers improve designs before manufacturing expensive tooling. With the moving object model, FLOW-3D CAST is able to accurately capture the fluid motion throughout the process, giving engineers insight from the actual ladle pour to the fast shot. Simulation courtesy of Mr. Antoni Drys from Nemak Poland Sp. z o.o.

Gravity Casting

A gravity casting simulation compared with the reconstruction of the real filling, based on thermocoupled data. Courtesy of XC Engineering and Peugeot PSA.

Foundry: Simulating a Flow Fill Pattern

Simulating a flow fill pattern
X-ray validation of a sand mold filling

Side-by-side comparison of X-ray fill and a FLOW-3D CAST filling simulation. Three-dimensional gravity filling of a sand mold with A356 aluminum alloy. The color is metal pressure. Simulation results are shown in the vertical plane of symmetry. X-rays courtesy of Modeling of Casting, Welding, and Advanced Solidification Processes VII, London, 1995.

HPDC: Flow Pattern

HPDC simulation flow pattern
Short sleeve validation – simulation versus casting part

Short shot compared to simulation results show good correlation. Courtesy of Littler Diecast Corporation.

Modeling Air Entrapment

Metalcasting defect validation
X-ray vs. FLOW-3D CAST validation of an oil filter housing for a diesel engine.

X-ray validation of an oil filter housing for a diesel engine, 380 die cast alloy. Results are colored by percent of entrained air. The detailed area in the X-ray shows the maximum porosity concentration.

HPDC Filling

Short shot high pressure die casting validation
HPDC casting validation comparing FLOW-3D results to the actual part

Short Shot Simulation

Simulation versus shortshot validation
Validation snapshots of actual casting parts vs. FLOW-3D CAST simulations. From left to right: A transmission housing, an oil pan and an auto part.

HPDC Air Entrapment Defects

Antrametal hpdc air entrainment cfd validation
Successful comparison of casting simulation versus experimental results courtesy of Antrametal.

This customer validation courtesy of Antrametal shows a comparison of simulation to experimental results using FLOW-3D CAST‘s Air Entrapment model. It is an HPDC of a front cover to an electric motor for a washing machine. The air-related defects are shown qualitatively in the coloring of the image. Physical air pockets captured by other numerical capabilities within FLOW-3D CAST are also clearly represented.

Core Drying

BMW core drying validation
A comparison made by BMW between simulation and experiment of the drying of an inorganic core.

Predicting Die Erosion

Die erosion validation
The area of die erosion due to cavitation was correctly located in a comparison of FLOW-3D Cast results to a real-world case.

Predicting Lost Foam Filling

Comparison of real time X-ray and FLOW-3D CAST metal flow simulation results on a lost foam L850 Block Bulkhead Slice. Simulation courtesy of GM Powertrain.

Porosity Defects

Porosity due to entrained air
Porosity due to entrained air

Predicting Shrinkage Porosity

Shrinkage porosity A380 diesel engine block casting
A380 diesel engine block casting