Each internal defect can affect the mechanical properties, lifespan, and safety of the final part. This is precisely why advanced simulation technologies, which enable the analysis of the entire casting process before production even begins, are becoming an increasingly important part of modern foundry practice. Software MAGMASOFT is primarily used in the production of complex-shaped castings for the aerospace industry using the investment casting method. The aim is to minimise the number of physical samples, shorten the technology development time, and at the same time achieve the highest possible quality while minimising costs.
Digital twin of the casting
The whole process begins with importing the 3D model of the casting and the gating system from the CAD system. The software then creates a detailed computational mesh on which the simulation of mould filling and material solidification takes place. The more complex and thin-walled the casting is, the more demanding the calculation the software must perform.
The simulation incorporates the precise material properties of both the alloy and the ceramic shell. The correct setting of thermophysical parameters is crucial for a realistic result. In the production of precision castings, the thermal conductivity of the ceramic mould and the cooling rate in individual parts of the casting are decisive.
Identifying problems before production
A major advantage of simulations is the ability to “look” inside the mould during the casting process. The software predicts the occurrence of defects that would otherwise only be detected during X-ray inspection or mechanical testing of the finished part after casting.
Among the most commonly monitored parameters are macro-porosity and micro-porosity, i.e. various types of cavities formed during the solidification of the material. Simulation also helps to identify turbulent air entrapment that occurs during mould filling, which can cause oxide entrainment and the formation of other internal defects. Analysis of the material structure also plays a significant role, directly affecting the final mechanical properties of the casting.
Thanks to simulation, the technology can be optimised even before the first casting is produced. In many cases, the first physical casting is also the final solution ready for mass production, significantly reducing the time and cost of technology optimisation.
Less waste, lower costs
Simulations have a significant benefit not only in terms of quality, but also in terms of cost-effective production. Aluminium is one of the most energy-intensive materials, and every extra gram means higher costs.
MAGMASOFT enables the optimisation of riser and gating system sizes so that the maximum amount of material is utilised right in the casting. The result is a lower amount of returnable material, reduced energy consumption, and at the same time a lower carbon footprint of production.
Autonomous optimisation: when variants are sought by software
Modern simulations are no longer just a passive tool for design verification today. MAGMASOFT can automatically evaluate dozens of technological solution variants and search for the optimal combination of parameters.
For example, from the specified range of pouring temperatures, riser sizes or pouring times, the software performs a series of simulations. The result is a detailed analysis that will show the most suitable option in terms of quality, yield, and production costs.
An important tool for the aviation and defence industry
In the aviation industry today, simulations are not just a technological advantage but often a crucial part of the certification process. The ability to provide the customer with detailed simulation analyses significantly increases the supplier's credibility and facilitates meeting the strict requirements of global aircraft manufacturers.
Modern foundry operations are increasingly moving into the digital environment, where quality is determined even before production begins. And it is precisely the ability to combine the expertise of technologists with computational tools that often determines who succeeds in the most demanding industrial sectors today.
