The following examples demonstrate how our customers successfully exploit MAGMASOFT® in order to realize better casting quality, cost savings or reduction of development times especially in the area of steel casting.

Working Under Pressure

Blind risers can only work properly for the limited number of cast alloys with a strong tendency to form a solid skin during solidification, such as steel alloys. This skin formation means that shrinkage in the casting leads to an under-pressure in those areas where feeding is needed.

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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.

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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.

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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 distortion and reduce machining allowances as much as possible.

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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.

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