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.
When less is more
Producing large ductile iron axle housings can be a challenging task. The part shown above was well into production when a shrinkage defect was noticed during machining. After several attempts to find a solution, the foundry contacted MAGMA to evaluate the part design.
Engine blocks full of stress
Cast iron engine blocks can be found in more than half of all passenger cars. Their performance and weight are, among other criteria, dependent on their geometry and the casting process, especially defects like porosity and residual stresses.
Castings with a tailwind
The world‘s leading manufacturer of wind power turbines, Vestas Wind Systems A/S, with its headquarter in Jutland, Denmark, strongly supports the development of wind power casting technology. The subsidiary Vestas Castings Group AS is the key supplier of castings for their wind power turbines. Compared to welded parts, castings offer much ...
Getting it right the first time
Risering of castings is supported through the determination of the local thermal modulus. This modulus describes the relationship between the heat content of a volume and the cooling power of the surrounding surfaces. For example, the hot spot with the largest thermal modulus (in this case 1.13 cm) must be fed by a riser with a higher modulu...
Going with the flow and fighting for air
Estimates say that 20 % of the costs of producing steel castings can be traced to inclusion removal and weld repair. Reoxidation inclusions, which form through melt contact with the air during pouring, make up a majority of steel casting inclusions.
- 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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