ICAST's knowledge in the area of casting simulations guarantees a stable process. Determining the proper casting configuration during production is a relatively complex process and the results are not always known beforehand. The casting process therefore needs to be simulated with a computer program. A casting simulation is a 3D model, which simulates the entire casting process. ICAST has used the same simulation software for many years and has built up considerable practical experience and knowledge. Casting simulations provide a high degree of process certainty, prevent technical problems and ensure that a project does not encounter delays.
Below Figure shows the simulation of investment casting of a nozzle. It shows the temperature distribution in liquid metal after cavity filling, and the progress of solidification pattern, predicted by investment casting simulation. Using simulation technique, the defects were predicted (specifically, air entrapment, shrinkage porosity in this case study). Gating design was iteratively changed using casting simulation for gating system optimisation. At ICAST we have worked on many such projects of investment casting.
The combined metallurgical behaviour and properties of the casting that is being produced is analysed and it can be adapted on the basis of geometrical features and historical behaviour of the casting.