Solving Internal Casting Defects

Triumph in England is a strong advocate of MAGMASOFT® and asks all suppliers of critical components, like the fuel distributor housing shown here, to use casting process simulation.

During casting trials, porosity was found in a critical location. This problem could be avoided by applying stronger die cooling in this area. Simulations were carried out both with and without the cooling.

The results showed porosity when no cooling was used and that the cooling would correct the problem. A second simulation was used to optimize the time for which the added cooling should be active. The objective was to determine if the porosity behavior would be identical if the cooling was only activated after the die was filled, in order to give other areas of the die enough time to be cooled. A further modification for this die casting was increasing the rib thickness near the problematic area to improve both the filling and solidification patterns.

Fuel distributor housing with internal porosity (left) and simulation results indicate the porosity and showed that additional cooling could eliminate the defect (right)

* Courtesy of Triumph, UK