Course Outline
1. Advanced View of Casting Defects
Objective: Accurately interpret how shop-floor defects manifest in simulations.
- Classification of casting defects
- Relationship between defect, process, and design
- Risks of misinterpreting simulation outputs
2. Filling Problems and Flow Risks
Objective: Proactively identify defects caused by flow issues.
- Turbulence and air entrapment formation
- Insufficient or uneven filling
- Impact of gating design on flow
- Advanced analysis of NovaCast filling results
Application:
Problematic filling example → design revision → re-simulation
3. Feeder (Riser) Problems
Objective: Understand the root causes of shrinkage and feeding insufficiency.
- Feeder placement and sizing errors
- Feeder-part relationship
- Logic of modulus and feeding continuity
- Feeding efficiency analysis via NovaCast
Application:
Feeder optimization and comparative scenarios
4. Risk Mapping and Preventive Approach
Objective: Use simulation as a tool for preventing defects, not just finding them.
- Early detection of high-risk areas
- Impact of parameter changes on risks
- Implementable preventive actions for the shop floor
5. Shrinkage and Porosity Problems
Objective: Correctly analyze the most critical quality issues.
- Types of shrinkage and formation mechanisms
- Hot spots
- Solidification sequence and directional solidification
- Interpretation of NovaCast shrinkage results
6. Solidification Behavior and Thermal Balance
Objective: Observe the impact of cooling and solidification on casting quality.
- Cooling rates and mold effects
- Thermal imbalances
- Logic of using chills
- Comparison of solidification scenarios
7. From Simulation to Shop Floor: Implementable Solution Paths
Objective: Effectively translate simulation results into production.
- “If it works in simulation, can it be applied on the shop floor?”
- Solution paths based on design, process, and parameters
- Revisions compatible with shop-floor realities
- Most common application errors
8. Closing Exercise: Advanced Analysis Through a Real Problem
Objective: Directly connect the training to shop-floor application.
- Real or representative casting problem
- Advanced analysis via NovaCast
- Comparison of alternative solution scenarios
- Selection of the most implementable solution
Requirements
Prerequisites
- General understanding of casting processes and fundamental metallurgical principles
- Experience working with basic casting simulation concepts and simulation outputs
- Programming knowledge is not required
Audience
- Process engineers who actively manage casting processes on the shop floor
- Technical staff working in casting quality, production, and R&D teams
- Casting operators and technical specialists who wish to use NovaCast simulation for quality improvement and error prevention
