Case Studies
The following examples demonstrate how our customers successfully exploit MAGMASOFT® in order to realize better casting quality, cost savings or reduction of development times.
Extending die life by eliminating cavitation
The cover and ejector halves of a high pressure die casting die showed severe cavitation erosion. An evaluation of the filling process using MAGMASOFT® immediately showed an undesirable cavity filling pattern and extremely high gate velocities in combination with air pockets above and below the melt stream.
Analysis of transmission case shrinkage defects
In a high pressure die casting for a transmission case, a shrinkage defect was revealed after drilling of the boss. Due to the current die design, it was not possible insert a pin into the die, making drilling of the boss the only option for this casting.
Solving casting surface defects
The wall thickness of this speaker housing was very thin at about 1.35 mm over most of the surface. There were several problem experienced in production. Blisters would occasionally develop on the exterior surface leading to casting rejection. Cold shuts formed in the side walls, and the filling was incomplete or had cold shuts on the top si...
Casting distortions during solution treatment
Aluminum castings are often heat-treated to increase mechanical properties and simultaneously decrease thermal stresses induced by the casting process. The heat treatment process consists of 3 steps. First is solution treatment, where the part is heated to a temperature near the solidus temperature of the alloy. Next the part is quenched, wh...
- Die casting
- Casting quality
- Cast component optimization
- Profitability and resource efficiency
- Casting design
- Automotive applications
- Heavy industries and wind power
- Permanent mold
- Cast iron
- Steel
- Nonferrous
- Core and mold
- Tool and pattern making
- Heat treatment
- Microstructure and properties
- Stresses and distortion
- no category
