See some of the most relevant publications about MAGMA applications and developments.

Simulation Evolves to Autonomous Optimization

Today’s requirements on the development of a casting and the corresponding metal casting process demand methodologies and tools which allow a maximization of process robustness and profitability at the earliest possible point in time. Opposed to real-world trials, autonomous optimization using simulation tools provides significantly more flexibility.

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Design Optimization of Heat Treatment Support Frames for Aluminum Alloy Structural Cast Parts Using Virtual Experimentation

The work shows how heat treatment support frames can be optimized by virtual experimentation using an integrated simulation approach. A unified creep material model is applied to model the distortion of an industrial thin-walled aluminium structural die cast part. The changing part deformation during the entire casting and heat treatment process as well as the effects of different supporting frame concepts on the distortion will be discussed. The predicted part deformation is compared for different supporting frame designs and is quantitatively assessed using a virtual 6-point (Reference Point System) measurement device.

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Heat Treatment of Steels – Optimization of Microstructures, Mechanical Properties, Stresses and Distortions by Virtual Optimization

Cast steels are characterized by a large variety of mechanical properties and microstructures after the heat treatment process in dependence on their final application. Process variations like differences in austenitization time and temperature, cooling conditions and chemical compositions play the significant role for high quality cast products. Process simulation with MAGMASOFT® is able to predict phase contents as well as mechanical properties including theses process variations in heat treatment and supports therefore a robust industrial heat treatment process design. Industrial examples for microstructure optimization of cast steels for a chain link will be given within the paper.

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Process Optimization for an Energy Efficient Heat Treatment of ADI

Austempered ductile iron (ADI) materials show a good combination of mechanical properties, with high tensile strength levels (800 - 1600 MPa) and an elongation at fracture of up to 10%. Due to its high fracture toughness as well as high fatigue resistance, ADI is a very attractive material group for applications under cyclic loads. However, the material properties are very sensitive to the applied process conditions during heat treatment. The basis for a substantial increase in the application of ADI materials in the industry requires the establishment of a predictable and robust process design. Here, an integrated process simulation of the heat treatment process coupled to required information about the as-cast quality of the component would aid in understanding process dependencies and defining a robust process window.

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Reduction of Oxide Inclusions in Aluminum Cylinder Heads through Virtual Design of Experiments

It will be shown in this paper that virtual design of experiments (vDOEs) are leading to optimized gating designs and process parameters resulting in a significant reduction of oxides in castings. The experiments supported by simulation were accompanied and validated by high-speed video technology and the PREFIL-measurement technology.

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Automatic Virtual Optimization of Ingot and Continuous Casting Processes

Simulation technology today makes it easily possible to carry out three-dimensional simulations of the teeming and solidification of ingots as well as of the flow and solidification in continuous casting processes. Quick and reliable virtual casting trials in the computer can be performed considering all relevant process parameters.

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Quality Prediction Through Combined Simulation Of Ingot Casting And Forging

The final quality of forged steel products is the result of a series of production process steps. After steelmaking, the molten metal is tapped from a ladle and poured into a mould, where it solidifies and cools. The solidified ingot is then brought to its semi-finished shape through a series of reheating and forging steps. Each individual step in this process chain influences the final product quality. Many defects in forged or hot rolled products originate from the casting process. Simulation is the state-of-art tool to investigate, understand and predict the effects of production processes on product quality.

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Practical Use of Core Simulation for Process Optimization

Simulation of the production of sand cores is a new method for fundamentally changing tool and process design by exploiting insights into core-shooting and hardening processes. Important factors affecting the quality of the core can be determined and quantified in advance of tool production and serial manufacture. The system’s physical basis and targeted procedures allow predictions to be made regarding the technical and economic feasibility of sand cores.

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Material Combinations in Lightweight Casting Components

Aluminum und magnesium castings play a major role in light-weight casting. These fields of application are being extended continually, and the specific demands on materials are increasing. More often the mechanical and tribological properties of the casting materials are insufficient, the operating temperatures are too high, or the environment shows a high level of chemical aggression. Local components can then be tailored to specific demands by cast-in inserts mostly made of steel or cast iron, depending on the requirements.

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Optimization of Ingot Quality Using Evolutionary Algorithms

This paper presents findings and results of a fully coupled 3-D numerical simulation of the manufacturing process of a three ton large steel ingot. Simulation of the teeming process as well as several thermal criterion functions together with solidification calculations are utilized for predicting the occurrence and distribution of various casting discontinuities and defects such as shrinkage and centerline porosity inside the considered ingot. The original ingot layout and its process parameters are then subjected to fully automated computer optimization. This is accomplished by coupling the casting simulation software package MAGMASOFT® with an optimization engine based on genetic algorithms.

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