Computer simulations of various processes have been used in the metallurgical industry for quite some time. Simulations for steel, iron and aluminum castings for automotive & aircraft parts are performed to study various casting phenomena so as to achieve castings with significant weight reduction and superior quality.

Several casting simulation software packages are available. RapidCast® was developed by Concurrent Technologies Corporation, and is licensed by Mountain Top Technologies, both of Johnstown, PA. The software uses the finite difference method to solve the differential equations that describe fluid flow and heat transfer in the casting process. In this study RapidCast® was used to evaluate precious metal investment casting common in jewelry manufacture. This research is still in progress and this paper describes the initial features of the simulation software.

Computer simulation allows visualization of the effects of casting design decisions. The results are in the form of three dimensional color images of the cast part. For example, the color of the part may, at the user's descretion, indicate the temperature or the porosity of the part. Incomplete filling due to cold shuts or trapped gas are revealed. Their locations suggest possible design modifications. The micro structure of the final product may also be determined if nucleation and grain growth constants for the alloy are available.

The results of changing casting parameters such as sprue or gate locations, pouring temperature, flask temperature, and alloy composition may be determined.

Authors: Dr. Stanley M. Howard, Ajit Menon