Foundry Images


The images below demonstrate how casting defects, even when hidden from sight, can be predicted using an appropriate technique.

Image 1: SOLIDCast prediction of material density loss or shrinkage is shown by Red Zones. These identify where the last metal to freeze is not being 'fed' from a large enough liquid-containing feeder.SolidCast Example

Image 2: Massive shrinkage at the centre-line of the casting is predicted by a SOLID-Cast plot of Niyama Value, shown as a turquoise coloured lamellar defect.

SolidCast Example

SOLIDCast - Casting Simulation Software

  • Works on low cost PCs – desktops or laptops.
  • Software costs less than £10,000 in UK.
  • Only 2 day’s instruction required by most users.
  • Has its own inbuilt 3D CAD modelling so you can easily create runner/riser systems or amend customer supplied models. Note: only STL (Stereo Lithographic) file format is supported.
  • Has an innate meshing system for converting a 3D ‘shape-enclosing-surface’ into a true solid form, utilizing numerous tiny cubes.
  • Has an integral mould-filling and metal freezing algorithms.
  • Simulates behaviour of all casting alloys – grey iron, ductile iron, steels, stainless steels, nickel-base, cobalt-base, aluminium-base, copper-base, magnesium, zinc-base, etc.
  • Contains a data base including hundreds of alloys– it is fully customizable so you can add your own data, expertise and experience.
  • Contains Riser Design and Gating Design Wizards, which allow rigging of new castings within minutes using 3D CAD models. This facilitates use of real process data rather than guesses based on simple geometry.
  • Utilizes numerous methods of gauging casting quality including:
    • Material density (loss)
    • Niyama Criterion
    • FCC Criterion
    • Critical Fraction Solidification Time (CFST) plotting
    • Hot Spots
  • The system is incredibly simple to understand and can be learned quickly.
  • Output (for supply to customers) via photographs and video clips.
  • Simulates all casting processes except high pressure diecasting.
  • Support is available via email, phone and remote-keyboard-internet.

SOLIDCast Simulations

In the example below a videoclip of a casting shows where problems will lie. This large iron casting poured into a silica sand mould shows an isolated hot-spot below the feeder head. Playing the videoclip shows exactly how it forms and if compared with Image 1 (see the right sidebar) which illustrates a density loss defect in the same casting the story is clear. Insufficient liquid metal and poor feeding cause the loss of material density that we call 'shrinkage'.

By increasing the feeder size from 90mm diameter to 127mm, as per SOLIDCast Wizard recommendations, the feeding of the casting becomes virtually perfect in the CFS Time videoclip. The previous 'pinch-off' of liquid metal feed is now absent and a sound casting is produced.