Steel

MAGMASOFT® 6.0 - MAGMA Steel HT – Now for More Alloys

MAGMA Steel HT offers steel casters a more extensive range of alloys that can be used for the simulation of heat treatment processes. In addition, new, alloy-dependent results support more accurate predictions regarding microstructures and casting properties during and after heat treatment, for example, the austenite or martensite start temperatures.

Optimized Production of High Quality Steel Castings

The quality and profitability of steel castings are driven by the design of the pattern, the productivity of the process, reproducible manufacturing conditions and the properties of the cast material after casting and heat treatment.

MAGMASOFT^® is capable of autonomously establishing robust process conditions and optimized solutions for the pouring, solidification and heat treatment of steel 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:�

optimization of gating/rigging for improved steel cleanliness and surface quality
elimination of shrinkage and porosity maintaining high yield levels
prevention of critical phases during metal cooling including convection and segregation effects
casting design features such as minimized risk of hot tearing and dimensional tolerances
resource conserving heat treatment processes tuned to achieve the desired microstructure and the required properties

Mold filling of a turbine housing

This inclusion tracerresult shows the Re-oxidation formation on the melt front of a steel alloy

Filling and cooling of the melt during casting

Quantitative prediction of cold lap tendency in thin-walled steel castings as a function of varied filling conditions, superheat of the melt and cooling power of the mold.

Distribution of reoxidation inclusions on the casting surface

Surface area fraction of the casting affected by re-oxidation inclusions for different gating system designs

Porosity indications

Autonomous Optimization for determining the required number of feeders

Manganese concentration profile after solidification

Predicting under-riser segregation considering feeding and convective flows

Sand burn-on and penetration tendencies

Hot tear prediction and reality

Autonomous Design of Experiments for different casting and methoding designs

Automatic search for the best compromise between feeding of shrinkage and hot tearing

Local mechanical properties after heat treatment, here tensile strength

Prediction of phases during heat treatment

Prediction of martensite as a function of carbon content and quench intensity

MAGMASOFT®’s unique integrated methodology of virtual experimentation and autonomous optimization lets the software automatically run through various steel 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 the driving forces decisive for steel casting quality.

This makes MAGMASOFT® key for cast steel part designers, pattern makers and foundrymen to lay out optimal cast part designs, implement reliable production processes, minimize quality risks, set up reliable process windows and realize the full potential of cast steel materials.�