The quality and profitability of iron castings are driven by the metallurgy of the melt, the design of the pattern, the productivity of the process, reproducible manufacturing conditions and the resulting properties of the cast iron material after casting and heat treatment.
MAGMASOFT®, with the latest version and its related modules, are capable of autonomously establishing robust process conditions and optimized solutions for the pouring, solidification and heat treatment of all cast iron alloys. The integrated tools to statistically set up virtual Designs of Experiments and automatically assess results support foundrymen in determining optimal design and process conditions, for example regarding:
MAGMASOFT®’s unique integrated methodology of virtual experimentation and autonomous optimization lets the software automatically run through various iron casting design and parameter combinations. MAGMASOFT® helps identify a set of process conditions best meeting the specified requirements. This is done quickly and comprehensively, matching different objectives considering all driving forces decisive for iron casting quality.
This makes MAGMASOFT® key for casting designers, pattern makers and foundrymen to lay out optimal cast component designs, implement reliable production processes, minimize quality risks, set up reliable process windows and realize the full potential of cast iron materials.
Cold Laps in Cast Iron
DANA Spicer has used MAGMASOFT ® to develop unconventional gating systems for ductile iron components for the heavy truck industry. In one case, they used simulation to check filling patterns and optimize the gating system of a ductile iron carrier. In production, the casting had a scrap rate of around 17%.