Course Outline
1. Advanced View on Casting Defects
Objective: Accurately interpret how real-world defects manifest in simulations.
- Categorization of casting defects
- Relationship between defect, process, and design
- Risks of misinterpreting simulation outputs
2. Filling Problems and Flow Risks
Objective: Identify flow-related defects early.
- Turbulence and air entrapment formation
- Insufficient or uneven filling
- Impact of gating system design on flow
- Advanced analysis of NovaCast filling results
Application:
Problematic filling example → Design revision → Resimulation
3. Feeder (Riser) Problems
Objective: Understand the root causes of shrinkage and feeding deficiencies.
- Feeder placement and sizing errors
- Feeder-part relationship
- Mechanics of modulus and feeding continuity
- Feeding effectiveness analysis via NovaCast
Application:
Feeder optimization and comparative scenarios
4. Risk Mapping and Preventive Approach
Objective: Use simulation not just to 'find defects', but as a preventive tool.
- Early detection of high-risk areas
- Impact of parameter changes on risks
- Implementable preventive actions in the field
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 influence
- Thermal imbalances
- Rationale for using chills
- Comparison of solidification scenarios
7. From Simulation to Field: Implementable Solutions
Objective: Effectively translate simulation results into production.
- 'If it works in simulation, is it applicable in the field?'
- Solution paths based on design, process, and parameters
- Revisions compatible with field realities
- Most common implementation mistakes
8. Closing Session: Advanced Analysis Through a Real Problem
Objective: Connect the training directly to practical application.
- A real or representative casting problem
- Advanced analysis via NovaCast
- Comparison of alternative solution scenarios
- Selection of the most implementable solution
Requirements
Prerequisites
- A general understanding of pouring processes and fundamental metallurgy principles
- Experience with basic casting simulation concepts and working with simulation outputs
- No programming knowledge required
Audience
- Process engineers who actively manage pouring processes in the field
- 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 defect prevention
