Yet, even with the optimized chemical compositionm, it became clear that despite some improvements the defect would still be present at an unsatisfactory high level. Therefore, Demisaş decided to run another DOE considering the feeder position as a variable.
The first DOE indicated the casting quality was not very sensitive to the feeder size. Therefore, the engineers concluded that the problem was mainly due to the feeding distance. Consequently, the feeder location was varied. As quality criteria, Fraction Liquid, Porosity and Hot Spot FS time were all selected to assess the outcome. Four designs were run with both filling and solidification.
After this successful case, Demisaş decided to apply the methodology of MAGMASOFT® autonomus engineering for other problematic patterns and to review their development processes for new patterns to work more effectively.