Steel Casting Publications

See some of the most relevant publications about MAGMA applications and developments especially in the area of steel casting.

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.

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.

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.

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.

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.