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.
Head block distortion
Many large steel castings are produced with large machining allowances, which directly results in higher production costs. One reason for including this overstock material is uncertainty regarding the non-uniform distortion of the casting during solidification and cooling. Looking to reduce costs, Dedini Foundry used simulation to predict d...
Squeezing more out of a highly developed process
The production of ingots used to provide billets for many forging operations is a highly evolved process. However, it is very difficult to find additional improvements to maximize the useable volume of the ingot. The goal is to minimize the areas affected by shrinkage defects and to avoid segregation, as it leads to inhomogeneous material p...
Air porosity reduction
WEG is a major electric motor manufacturer in Brazil with captive iron and aluminum high pressure die casting foundries. The die casting foundry was facing a 25 % scrap rate for a two-cylinder compressor. Their client did not accept any porosity on the machined faces of the casting.
Slag defects in plates
Steel foundries producing large components often pay more attention to the solidification process and less to the gating and the filling pattern of the casting.
Reducing of shrinkage defects in a valve body
Normally it is not possible to avoid shrinkage problems in thicker wall sections in high pressure die castings. This occurs because the feeding pressure cannot compensate for shrinkage once the ingate has frozen.
- 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
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