Course Outline
1. Advanced Perspective on Casting Errors
Objective: Correctly interpreting errors encountered in the field from simulation results.
- Classification of casting errors
- Error-process-design relationship
- Risks of misinterpreting simulation outputs
2. Filling Problems and Flow Risks
Objective: Identifying flow-related errors in advance.
- Turbulence and air entrapment formation
- Insufficient or unbalanced filling
- Impact of gating design on flow
- Advanced analysis of NovaCast filling results
Application:
Problematic filling example → design revision → re-simulation
3. Feeder Problems
Objective: Understanding the root causes of shrinkage and feeding insufficiency.
- Errors in feeder placement and sizing
- Feeder-part relationship
- Module and continuous feeding logic
- Analysis of feeding effectiveness using NovaCast
Application:
Feeder optimization and comparative scenarios
4. Risk Mapping and Preventive Approach
Objective: Using simulation as a tool for error prevention, not just error detection.
- Identifying high-risk areas in advance
- Impact of parameter changes on risks
- Implementable preventive actions in the field
5. Shrinkage and Porosity Problems
Objective: Correctly analyzing the most critical quality problems.
- 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: Observing the impact of solidification and cooling on casting quality.
- Cooling rates and mold effect
- Thermal imbalances
- Logic behind chill usage
- Comparative analysis of solidification scenarios
7. From Simulation to Field: Implementable Solution Paths
Objective: Transferring simulation results correctly and effectively to production.
- “Correct in simulation → implementable in the field?”
- Solution paths based on design, process, and parameters
- Revisions compatible with field realities
- Common implementation errors
8. Closing Exercise: Advanced Analysis of a Real Problem
Objective: Directly linking the training to the field.
- A real or representative casting problem
- Advanced analysis using NovaCast
- Comparative analysis of alternative solution scenarios
- Selection of the most implementable solution
Requirements
Prerequisites
- General understanding of casting processes and basic metallurgical principles
- Basic concepts of casting simulation and experience working with simulation outputs
- Programming knowledge is not required
Audience
- Process engineers who manage casting processes in the field
- Technical personnel working in casting quality, production, and R&D teams
- Casting operators and technical experts who want to use NovaCast simulation for quality improvement and error prevention
