Inspire Cast Final PDF

Contents
About this Book............................................................................................................. 4

Acknowledgment ...................................................................................................... 6
Disclaimer.................................................................................................................. 7
1. History of Metal Casting ........................................................................................... 8
2. Metal Casting .......................................................................................................... 12
2.1 Introduction to Metal Casting ........................................................................... 12
2.2 Design Factors for Metal Casting ...................................................................... 14
2.3 Solidification of Metal Casting .......................................................................... 20
2.4 Niyama Criterion for Predicting Shrinkage Porosity ......................................... 22
2.5 Casting Processes .............................................................................................. 24
2.5.1 Sand Casting ............................................................................................... 24
2.5.2 Investment Casting ..................................................................................... 25
2.5.3 Die Casting .................................................................................................. 27
2.5.4 Gravity Die Casting ..................................................................................... 27
2.5.5 High Pressure Die Casting........................................................................... 28
2.5.6 Low-Pressure Die Casting ........................................................................... 29
2.5.7 Centrifugal Casting (Industrial)................................................................... 30
2.6 Casting Components ......................................................................................... 33
2.6.1 Core Plug .................................................................................................... 33
2.6.2 Riser Casting /Feeder ................................................................................. 33
2.6.3 Insulating or Exothermic Sleeve ................................................................. 37
2.6.4 Overflow Risers (Cavity/Passages) ............................................................. 38
2.6.5 Casting Coolers ........................................................................................... 39
2.7 Pouring Techniques ........................................................................................... 39
2.8 Molding ............................................................................................................. 42
3. Defects on Casting .................................................................................................. 43
3.1 Casting Defects Due to the Evolution of Gases ................................................. 43
3.1.1 Blow Holes .................................................................................................. 43
3.1.2 Pin Hole Porosity ........................................................................................ 44
1
3.1.3 Rat Tails or Vains Defects ........................................................................... 45
3.1.4 Dispersed Shrinkage ................................................................................... 46
3.1.5 Blister.......................................................................................................... 46
3.2 Casting Defects Due to Pouring of Melt ............................................................ 47
3.2.1 Mis-Run ...................................................................................................... 47
3.2.2 Cold Shut .................................................................................................... 48
3.2.3 Elephant Skin .............................................................................................. 49
3.3 Inclusions........................................................................................................... 50
3.3.1 Solid Inclusions ........................................................................................... 50
3.4 Casting Defects Due to Metallurgical Factors ................................................... 51
3.4.1 Hot Tears .................................................................................................... 51
3.5 Casting Defects Caused by Molding Materials .................................................. 52
3.5.1 Scab ............................................................................................................ 52
3.5.2 Metal .......................................................................................................... 53
3.5.3 Fusion ......................................................................................................... 54
3.5.4 Flash............................................................................................................ 55
3.5.5 Run Out ...................................................................................................... 56
3.5.6 Lug .............................................................................................................. 56
3.5.7 Shrinkage Cavity ......................................................................................... 57
3.6 Casting Defects Caused by Other Factors ......................................................... 58
3.6.1 Mismatch .................................................................................................... 58
3.6.2 Hot Cracking ............................................................................................... 58
4. Inspire Cast Modules............................................................................................... 60
5 Gravity Casting (GDC) ............................................................................................... 62
5.1 Introduction to Gravity Casting ......................................................................... 62
5.2 Defining Ingate Systems .................................................................................... 62
5.3 Gravity Casting Simulation Set-Up .................................................................... 63
5.4 Selection of Material ......................................................................................... 64
5.5 Pre-Process Parameters (Components)/Basic Set-Up ...................................... 65
5.7 Tutorial: Brake Caliper....................................................................................... 67
6 Low-Pressure Die-Casting (LPDC)........................................................................... 102
2
6.1 Setting up of LPDC ........................................................................................... 104
6.3 Tutorial: Wheel Rim ........................................................................................ 106
7 High-Pressure Die-Casting (HPDC) ......................................................................... 119
7.1 Setting up of HPDC .......................................................................................... 121
7.2 Tutorial: Wash Basin ....................................................................................... 123
8 Investment Casting ................................................................................................ 143
8.1 Introduction to Investment Casting ................................................................ 143
8.2 Tutorial: Brake Caliper..................................................................................... 145
9 Gravity Tilt Pouring ................................................................................................ 156
9.1 Introducing to Tilt Pouring .............................................................................. 156
9.2 Tutorial: Gear Housing .................................................................................... 159
Appendix A ................................................................................................................ 170
A 1. Set-Up ................................................................................................................ 171
Steps .................................................................................................................. 171
Setup Toolbar .................................................................................................... 171
Cast Part - Designate Casting Part ..................................................................... 171
Gate ................................................................................................................... 174
Designate Surfaces as Gates.............................................................................. 174
Component Cores.............................................................................................. 175
A 2. Geometry Modifications .................................................................................... 177
Geometry Setup ................................................................................................ 177
PolyNURBS......................................................................................................... 194
Cut and Simplify Tools ....................................................................................... 202
Simplify Tools - Partition Parts .......................................................................... 204
Mid-Surface and Fillet Tools .............................................................................. 204
Midsurface......................................................................................................... 205
Fillets ................................................................................................................. 206
3
About this Book
This book aims to focus on fundamental to advanced approaches into the exciting and
challenging world of Casting Simulation using Altair’s Inspire Cast. The main objective
of writing this book is to provide professional engineers, foundrymen and researchers
with a practice resource on the design and analysis of casting simulation, with recent
high utilization of casting structures in – automotive, aerospace, marine structures,
etc. This eBook is aimed at helping those engineers, foundrymen, and researchers to
help gain knowledge in a short period of time and focus on obtaining a practical
understanding of the software, basic knowledge of casting techniques and simulations
as opposed to real-life experimentation.
This book is written as a self-based training course which discusses the types of casting
and its different modules like gravity casting, low pressure die-casting, high pressure
die casting, tilt pouring and investment casting. This eBook also contains brief details
of history of metal casting, design of metal casting, solidification of metal casting,
Niyama Criteria, geometry modification, casting manufacturing process, designated
gating system for metal casting, defects during the casting, core plugs, centrifugal
casting for industrial applications, Die casting chillers, risers feeders, insulating and
exothermic sleeves, cavity/passages during casting, molding, casting coolers, short
sleeve and crucible pouring.
The developments in information technology, especially the steady and rapid
enhancement of speed and memory in affordable computers, have changed the world
of design and production of cast metal parts. Today, simulation is an essential tool in
modern foundries and cast shops for mold and process design, process control, and
design and process optimization. Based on a comprehensive literature survey and the
experience in using some of the available commercial codes, an attempt is made here
to summarize the concepts of modeling and simulation of the casting process to
enrich the knowledge of foundry engineers and researchers. In recent years,
simulation has been accepted as a standard tool in the new process development and
in-process optimization studies. Although, most of the foundry engineers are aware
4
of the tangible benefits of casting simulation, as per their survey, the use of simulation
software was only 30% compared to a 75% use of CAD/CAM software and 100% use
of the Internet. Conceiving these facts, this book summarizes the concepts of
modeling and simulation of the casting process to benefit the understanding of
students, foundry engineers and researchers.
Computer-aided casting design and simulation give much better and faster insight for
optimizing the feeder and gating design of castings. Key inputs, steps, and results are
discussed in this book. Casting simulation, however, poses several challenges:
technical as well as non-technical (resources) for students and industrial users. We
highlight the best practices based on our experience with several casting theoretical
simulations of Altair Inspire Cast, and directions for further research in this area to
make casting simulation more easy, accessible and economical for industrial users.
Thanks, Altair University Team
“The more that you read, the more things you will know. The more that you
learn, the more places you’ll go”
- Dr. Theodor Seuss Geisel

Springfield Massachusetts, US
5
Acknowledgment
This book is a result of the joint effort of many colleagues who contributed in
numerous different ways to get this edition published.
• Sourav Das the Author of this eBook, for the entire content.
• Rahul Ponginan, for reviewing and editing this book.
• Pablo Manuel Torne Fernandez and Basavaraj Koppad for Review and
suggestions, Ravi Kunju, Martin Solina for their support
• Matthias Goelke, Rahul Rajan, Shannon Mistry, Priyanka Nagaraj, Smitha
Ramaiah, Prasanna Kurhatkar and Koushik Chandrashekar for their
constructive comments and warm encouragement.
• Nelson Dias, Pavan Kumar CV, Vishwanath Rao, Mike Heskitt and Sean
Putman, for their support.
• The entire Altair Inspire Cast Documentation Team, for putting together the
many pages of documentation.
Please note that a commercially released software is a living “thing” and so at every
release (major or point release) new methods, new functions are added along with
improvement to existing methods. This document is written using Inspire Cast 2019.2,
Any feedback helping to improve the quality of this book would be very much
appreciated.
Dr. Matthias Goelke

On behalf of the Altair University Team
6
Disclaimer
Every effort has been made to keep the book free from technical as well as other
mistakes. However, publishers and authors will not be responsible for loss, damage in
any form and consequences arising directly or indirectly from the use of this book. ©
2019 Altair Engineering, Inc. All rights reserved. No part of this publication may be
reproduced, transmitted, transcribed, or translated to another language without the
written permission of Altair Engineering, Inc. To obtain this permission, write to the
attention Altair Engineering legal department at:
1820 E. Big Beaver, Troy, Michigan, USA, or call +1-248-614-2400.
7
1. History of Metal Casting
(This chapter is entirely based on History of Metal Casting-http://www.metal-
technologies.com/docs/default-source/education/historyofmetalcasting.pdf )
Metal casting has played a critical role in the development and advancement of human
civilization and culture since its discovery. Metal casting plays an important role in our
everyday lives and is more essential than it has ever been. Origins of Metal Casting was
recorded 3200 B.C, a copper frog, the oldest known casting in existence. Iron was
discovered in 2000 BC. The first Chinese production of cast iron was found in 800-700 B.C.
Sand molding was known in 645 B.C in China. In 500 A.D, cast crucible steel was first
produced in India, but the process was lost until 1750 when Benjamin Huntsman
reinvented it in England.
Middle Ages to 1800
In 1455, Dillenburg Castle in Germany was the first to use cast iron pipe to transport water.
Vannoccio Biringuccio (1480-1539), the "father of the foundry industry," in Italy was the
first man to document the foundry process. In the year 1642, Saugus Iron Works,
America's first iron foundry was established near Lynn, Massachusetts. The first American
iron casting, the Saugus pot, was made. In 1709, Abraham Darby created the first true
foundry flask for sand and loam molding. In 1720, Rene Antoine de Reaumur developed
the first malleable iron, known today as "European Whiteheart cast iron". In 1730,
Abraham Darby is the first to use coke as fuel in his melting furnace in England. In 1750
Benjamin Huntsman reinvented the process for making of cast crucible steel in England.
This process was the first, in which the steel is completely melted, producing a uniform
composition. Since the metal is completely molten, it also allowed for alloy steel
production, as the additional elements in the alloy can be added to the crucible during
melting. In 1794 First use of the Cupola in an iron foundry.
The 19th Century
A.G. Eckhardt of Soho, England in 1809 was the first to develop Centrifugal casting. In the
year 1815, the cupola is introduced in the United States in Baltimore, MD for steel
8
production. First cast steel was produced in 1818, by the crucible process in the U.S. at
the Valley Forge Foundry. In 1825 Aluminum, the most common metal in the earth's crust
is isolated. 1826 Seth Boyden of Newark, NJ, is the first to develop a process for and
produce "blackheart" malleable iron. 1831 In Cincinnati, OH, William Garrard establishes
the first commercial crucible steel operation in the U.S. In 1837 First dependable molding
machine is marketed and used by the S. Jarvis Adams Company in Pittsburg. In 1845 The
open-hearth furnace is developed. 1851 Sir Henry Bessemer and William Kelly both invent
a simple converter that uses blasts of air to burn out the impurities such as silicon,
manganese and excess carbon in the pig iron. Although Kelly is the first to use a converter,
Bessemer obtains the U.S. patents. 1863 Metallography, the etching, polishing, and
microscopic evaluation of metal surfaces are developed by Henry C. Sorby of Sheffield,
England. It is the first process to physically examine the surface of castings for quality
analysis. 1867 James Nasmyth develops a gear-tilted foundry ladle, increasing worker
safety, and operational economy. 1870 Sandblasting is first used to clean large castings by
R. E. Tilghman of Philadelphia. 1880-1887 The Sly tumbling mill is developed. It is the first
cleaning machine for small castings. This mill greatly reduced the time needed for hand-
cleaning operations and produced a finer finished product. 1896 American Foundrymen's
Association (renamed American Foundrymen's Society in 1948 and now called the
American Foundry Society) is formed. In 1897 Investment casting is rediscovered by B.F.
Philbrook of Iowa. He used it to cast dental inlays.
Early 20th Century
In 1906, electric arc furnace was first used in the United States of America at Holcomb
Steel Co. in Syracuse, NY. 1913 First stainless steel was melted by Harry Brearley in
Sheffield, England in the tear 1913. Crucible Steel Casting Co.'s Lansdown, PA plant
installed the first low-frequency electric furnace for special melting purposes in 1913. The
International Committee of Foundry Technical Associations was formed in 1923 in Zurich,
Switzerland. In 1924 Dr. W.H. Hatfield invents 18/8 stainless steel (18% chromium, 8%
nickel). In 1930, the University of Michigan invented Spectrography for metal analysis. The
first high-frequency coreless electric induction furnace was installed in the US in the
Lebanon Steel Foundry in Lebanon, PA in 1930. In 1940 Wood floor was introduced into
foundry practice as a sand additive. 1947 the Shell Process was invented in 1947 by J.
Croning of Germany during World War II, is discovered by U.S. officials and made public.
9
1948 Development of ductile iron, a cast iron with a fully spheroidal graphite structure.
The ductile Iron was invented in 1949 and a U.S. patent was granted to K.D. Millis, A.P.
Gagnebin and N.B. Pilling of International Nickel Company. In 1953, the Hotbox system of
making and curing cores in one operation was developed, eliminated the need for
dielectric drying ovens. In 1958 H.F. Shroyer is granted a patent for the full mold process,
the expendable pattern (lost foam) casting process. In 1964 the first Disamatic
molding machine was introduced. In 1965 The Scanning Electron Microscope is
invented by the Cambridge University Engineering Department in England. In 1965
Cast metal matrix composites are first poured at International Nickel Company in
Sterling Forest, NY, by Pradeep Rohatgi. The Cold Box Process is introduced by L.
Toriello and J. Robins for high production core making in 1968.
Late 20th Century
In the early 1970s, the Semi-Solid Metalworking (SSM) process was invented at the
Massachusetts Institute of Technology. It combines the aspects of casting with the
aspects of forging. In 1971, the Japanese developed a Vacuum molding Process. This
method used unbonded sand and a vacuum. 1971 Rheocasting was developed at
Massachusetts Institute of Technology. In 1971 U.S. Congress passes the Clean Air Act
and OSHA, the Occupational Health and Safety Act. In 1972, the first production of
Austempered Ductile Iron (ADI) component was recorded by Wagner Castings
Company. In 1974 Fiat introduces the in-mold process for ductile iron treatment. In
1976 compacted graphite iron (CGI), an iron with elongated graphite particles with
rounded edges and roughened surfaces is developed in the U.K. It has characteristics
of both gray and ductile iron. The Warm Box binder system was introduced in 1982.
The first foundry application of a plasma ladle refiner (melting and refining in one
vessel) occurs at Maynard Steel Casting Company in Milwaukee, WI in 1993. In 1995
Babcock and Wilcox, Barberton, OH, patent a lost foam vacuum casting process to
produce stainless steel castings with low carbon content. In 1996 Cast metal matrix
composites are first used in a production model automobile in the brake rotors for
the Lotus Elise. In 1997 Electromagnetic casting processes developed by Argonne and
Inland Steel Corporation.
10
References:
(This chapter is entirely based on History of Metal Casting-http://www.metal-

technologies.com/docs/default-source/education/historyofmetalcasting.pdf )
11
2. Metal Casting
2.1 Introduction to Metal Casting
(This section is entirely based on Civilization of Metal Casting-
https://bernierinc.com/brief-history-metal-casting/)
The story of metal casting begins some five and a half thousand years ago in
Mesopotamia, the cradle of civilization. The process, which involves pouring molten
metal into a mold, was used by the Mesopotamians to create all manner of things
including tools and weaponry, typically out of the copper-tin alloy, bronze. Civilization
had finally dragged itself out of the Stone Age and metal casting was to play a
significant role. Within a thousand years, the Bronze Age had spread to most corners
of the globe. There is evidence that the Egyptians had invented bellows that allowed
them to heat the metal to temperatures previously unattainable. These primitive
devices were capable of pumping hot air into furnaces, revolutionizing the way metal
was worked and cast. There is evidence from this period, however, that the Hittite
empire was using a primitive batch method furnace.
Aluminum was named after alum, which is called 'alumni' in Latin. This name was
given by Humphry Davy, an English chemist, who, in 1808, discovered
that aluminum could be produced by electrolytic reduction from alumina
(aluminum oxide), but did not manage to prove the theory in practice. Aluminum has
several characteristics that can be controlled to maximize casting properties.
Specialized molten metals processing and casting techniques can help enhance
mechanical properties. Molten aluminum is sensitive to trace elements, but this
sensitivity can be used as an advantage by adding trace amounts of materials to create
beneficial changes in casting microstructure. Grain refining and silicon modification
can improve mechanical properties in the final component. During solidification,
aluminum freezes in long columnar grain structures. These grains will grow until they
impinge on another grain. The mechanical properties can be improved through
periodizing constituent phase particles and by precipitation hardening. The
relationships between microstructures and mechanical properties for cast metals and
12
alloys have been discussed by many investigators, and the relationships between
microstructure with solidification cooling rate for aluminum alloys have been
reported. With recent high utilization, the phenomenon of casting solidification
accompanied by volumetric contraction, leads to several major defects in casting
including shrinkage porosity, cracks, and distortion. In short freezing range alloys,
especially those poured in permanent molds, the shrinkage tends to concentrate at
the hot spots. In long freezing range alloys, especially those poured in sand molds, the
shrinkage tends to be distributed all over the casting, though more of it still appears
around hot spots. The location and extent of shrinkage porosity can be predicted by
identifying regions of high temperature (hot spots) and low gradients (short feeding
distance). Unfortunately, castings can be of complex shapes, and the heat transfer
from all faces of the mold may not be uniform. Other factors, such as air gap formation
at the metal-mold interface, convection in liquid metal, application of feed aids,
presence of cores, gating system design and pouring parameters also affect the
location of shrinkage porosity, making its prediction difficult, if not impossible,
manually.
In recent years, computer simulation of casting solidification has gained much ground,
owing to the constant and painstaking efforts of researchers to make such software
tools more reliable and easier to use. A significant number of real-life case studies are
also available in technical journals and proceedings of conferences related to casting.
Still, only a handful of aluminum foundries are using these software tools today. This
is owing to several challenges posed by first-time users. We first present an overview
of computer-aided methods. This is followed by the difficulties faced by foundry users,
and how to overcome them through best practices gleaned from our experience with
several simulation projects and consultants.
13
2.2 Design Factors for Metal Casting
The materials used for casting should be selected according to their physical,
mechanical properties and some chemical properties like melting point, corrosion
resistance, and tensile strength.
The metals used for casting are characterized by their casting properties like:
• Fluidity, Slag formation

• Solidification capacity,
• Pouring temperature.
The above factors affect the quality of the casting product by their Dimensional
strength & internal reliability.
Preliminary Design
• Geometry
Detailed Design
Conceptual Design • Materials
• Quality Analysis
Specification Optimization
• Product
Requirement
Methoding
Process Selection
Gating Design
Process selection Tooling type
Feeding Design
Process Parameters
Tooling Design
An efficient and experienced metal casting designer is always looking for a simple
mold that can produce a casting of the desired shape. A casting designer always looks
for energy efficient and a cost-effective process to make a component. The variables
in metal casting design are discussed in the following sections.
(K.G. Swift, J.D. Booker 1999,pg 336).
14
Fluidity may be defined as an empirical measure of the distance a liquid metal can
flow in a specific channel before being stopped by solidification. Fluidity can also be
defined as the ability of a liquid metal to flow freely and thus to feed a mold cavity
and produce the desired contour before freezing occurs.
Factors affecting fluidity:
Freezing range of alloy: Fluidity is inversely proportional to the freezing temp.
range.
Short Freezing Range: Total Fluidity Length: Lf = tf .V (tf is the time and v is
the velocity.
Long Freezing Range (Lf) = x. tf. V (x<1)
Alloy Composition: Eutectic composition has better fluidity
Inclusions: Insoluble particles can increase viscosity and decrease fluidity.
Surface Tension: Decreases fluidity
Latent heat of fusion of alloy: Higher latent heat increases fluidity(Si has higher
H than Al, Al-Si alloy has better fluidity.
Shrinkage is the contraction rate of molten metal as it is solidifying from the liquid
state. Liquid shrinkage describes the contraction rate when the metal first solidifies.
solidification shrinkage describes the point in time when the solid metal starts cooling.
Liquid shrinkage is taken care of by a riser and solid shrinkage is compensated by
proper pattern allowances
Slag or Dross: Slag and dros formation are mainly due to the presence of non-metallic
inclusions in a casting. In steel melting, the inclusions are lighter than the liquid metal
and float on the surface and are removed along with the slag/dross. Some of the
inclusion particles are trapped inside the liquid metal and are detrimental to the
properties. The slag inclusions can be removed by using ceramic filters.
Pouring temperature: Pouring temperature is the temperature at which a given

metal/alloy is poured in a mold for casting purposes. An experienced metal casting
engineer always checks the temperature before pouring the liquid metal into the
mold. This is one of the important parameters as far as the casting design is
15
concerned. Pouring temperature should always be 50-100 oC more than the melting
point of the metal/alloy.
Heat transfer: Heat transfer rates affect how quickly a metal solidifies within a mold. One
is the dispersion of heat of the metal through itself, and the other the rate of heat transfer
from where the casting touches the mold. Heat transfer in the liquid metal, at the
metal/mold interface, and heat transfer through the mold are the controlling parameters
to optimize the solidification rates. The heat transfer coefficient (h) is an important factor
for achieving defect-free casting. Metal is a better conductor than a mold. The
solidification rate depends upon the thermal properties of mold. As soon as the hot metal
at temperature Tm is poured in the mold, it immediately reaches at temperature Tm
within no time (t=0). The relation between the thickness of the metal solidified and the
time is given by the relation. The below figure shows the temperature – distance profile
of a casting process with thermal resistance at the mold.
2 (𝑇𝑚 − 𝑇0 )
𝑆= √𝐾𝑚 𝜌𝑚 𝐶𝑚√𝑡
√𝜋 𝜌𝑠 𝐻
Distance, x
Temperature – distance profile of a casting process with thermal resistance at the mold.
16
Where, s=thickness of metal solidified at a time ‘t’, TM is the melting point of the metal T0
is the ambient temperature ρs is the density of solid, ‘H’ is the heat of fusion, Km is the
thermal conductivity of the mold material, ρm is the density of mold material and cm is the
specific heat. S ∞ (t)1/2 This is valid for sand mold and high conductivity metals like Cu,
Al, Mg, etc. ‘S’ can be replaced by (Vs/A), where Vs is the volume of solidified metal at
time ‘t’ and ‘A’ is an area of mold/metal interface. Considering t=tf where ‘tf ‘is the total
solidification time for a volume of casting Vs,
𝑣 2 𝑇𝑀 − 𝑇0
= √𝑘𝑚 𝜌𝑚 𝐶𝑚√𝑡𝑓
𝐴 √𝜋 𝜌𝑠 𝐻
Metal Mold
Tf = C (V/A)2 where C is the constant (mold and metal), V is the volume and A is the
area of cross-section. This relation is known as Chvorinov’s rule. Using this rule, one
can find out the thickness of melt solidified in time ‘t’.
In die casting, the liquid metal solidifies immediately, as soon as it comes in contact
with the metallic die and here mold/metal interface is the controlling factor.
Resistance to heat flow across the mold/metal Interface is large compared to
resistance in the metal and in the mold and heat flow is h controlled. h is the heat
transfer coefficient. The relation between solidified metal and the time of
solidification is given by the relation.
tf = (V/A)(ℓs H)/ h(TM-To).
The temperature – distance profile is shown below
17
Temperature – Distance Profile in Die Casting
Solidification Patterns
Usually, a casting cools more quickly where it is touching the mold, crystallizing from
the edge inward. Knowing the crystallization, heat transfer, and shrinkage rates of a
given metal allow a design engineer to predict the pattern of crystallization through
the casting. When looking to minimize problems with shrinkage, molds are designed
with these solidification patterns in mind. Parts of the mold may be cooled with chills
to minimize shrinkage in a section. Other parts of the casting might be connected to
reservoirs, called risers, which slowly feed liquid metal into a cooling casting to
prevent cavities forming as the solidifying metal shrinks.
Mold Stability
The mold materials must be stable in all the severe casting conditions when the liquid
metal cools from its liquid state. The mold materials must be stable and not expand
due to absorbing heat from liquid metals. It should also have the property to release
gases evolving from the mold during pouring that gets trapped in the solidifying
casting. The materials used in the mold must be able to withstand the metal in all
states, without fracture or collapse.
18
Surface Finish Capability
Casting finish is one of the most important factors of product development. Different
molding methods produce various kinds of finishes. The cost of the product will be
high if one needs a fine finish. In some cases, the cast product is subjected to the
machine for a fine finish. Very smooth finishes tend to come from more intensive and
therefore more expensive molding processes.
Drafts
Drafts are the taper in the vertical walls of the casting so as to remove the casting
without breaking the side walls. Draft allowances are given in the pattern that are
replicated in the casting. These are necessary so that a pattern, which is the “positive”
image of the object being designed, can be removed without disturbing the walls of
the mold.
Cores
Cores are used in the casting processes to create intentional holes. After completion
of casting the mold along with the core and internal hole is exposed out. Core
dimensions are very carefully designed in order to get exact dimensions of the hole or
internal cavities.
While designing a product a detailed communication and exchange of scientific and

technical views among the designers, engineers, and casting people should be
organized to achieve a superior defect-free cast product.
19
2.3 Solidification of Metal Casting
Solidification process means crystallization of liquid metals/alloys to a solid phase
during the cooling process. Solidification of metals and alloys occurs by nucleation and
growth process. Hence cooling curve is an important phenomenon following the
transformation from liquid to solid. In general, the cooling curve is a graph between
temperature and time and represents the change of phase from liquid to solid. In pure
metals and alloys with eutectic composition, solidification occurs at a constant
temperature. In the case of alloys, the temperature does not remain constant during
solidification and it occurs over a range of temperatures. In pure metals, the free
energy of the liquid phase and the solid phase is the same at melting point and hence
liquid metal phase must undercool for initiation of solidification. Undercooling is the
Difference Between the Melting Point and the Temperature at Which Nucleation
Occurs as shown in Figure in the right end.
Cooling curve of pure metals Crystallization of pure metal
Reference : https://link.springer.com/chapter/10.1007%2F978-1-349-00088-3_1
20
Cooling curve of an alloy (left alloy phase diagram and right cooling curve.
Reference : https://iopscience.iop.org/book/978-1-6817-4473-5/chapter/bk978-1-
6817-4473-5ch3
At the melting point, the free energy of solid and liquid are the same and it is not
favorable for transformation. Hence, the liquid has to be undercooled to an amount
ΔT, as shown in Figure below. The ΔG is the driving force for solidification. If there is
no undercooling at the equilibrium temperature, no transformation can occur.
Free energy – Temperature diagram

Reference : http://www.ndhu.edu.tw/ezfiles/29/1029/img/2888/Chapter1.pdf
21
Once the condition of the spontaneous occurrence of phase transformation is
satisfied, the formation of solid starts. Further, more and more atoms from liquid
phase leave and join the solid phase. Transformation is taking place in two major
processes one is nucleation and the other one is growth. Nucleation refers to a
process in which very small solid particles known as nuclei are formed when the liquid
metals /alloys cooled below its liquidus temperature. Hence, nucleation is a process
in which a tiny solid exceeds a critical size. Below this critical size, it dissolves in liquid
and above this size, it becomes a solid particle. Nucleation generally takes place by
two major processes, one is homogeneous nucleation and the second one is
heterogeneous nucleation. Homogeneous nucleation occurs spontaneously without
the help of any addition of foreign particles. On the other hand, heterogeneous
nucleation occurs with the help of externally added particles such as a nucleating
agent. In Al alloys Ti compounds are used as a nucleating agent, in Mg alloy Zr, C is
used as a nucleating agent, in stainless steel Ca/Mg cyanides and in Cast iron, sulfur
compounds are used. Heterogeneous nucleation requires less supercooling. As soon
as the liquid metal meets the mold, it freezes immediately by a heterogeneous
nucleation process with equiaxed grains and this zone is referred to as a chill zone.
Then, the liquid solidifies by homogeneous nucleation as columnar grains from the
surface to the center. The remaining liquid in the middle solidifies as equiaxed grains.
These equiaxed grains are usually larger than the equiaxed grains in the middle of the
casting.
2.4 Niyama Criterion for Predicting Shrinkage

Porosity
The Niyama criterion is well-known for the shrinkage function prediction in steel
castings. The function is based upon the temperature gradient and solidification
rate/cooling rate. Niyama found that the temperature gradient divided by the
square root of the cooling rate predicts the presence of shrinkage defects in
castings. If the ration is lower ~0, then the probability of shrinkage defects is more
22
i.e. lower the Niyama value higher the probability of defects. When the ratio is 1 or
higher, there is little or no shrinkage porosity in the castings. A value of Niyama
function ~0, predict the higher probability of the presence of solidification shrinkage.
However, one must take a detailed interpretation of the Niyama criterion for
prediction of shrinkage. The Niyama criterion is based only on heat transfer and
does not consider the effect of gravity. Niyama criterion, however, is still used
extensively in many non-ferrous applications (typically in aluminum alloys).
Micro-shrinkage porosity in aluminum casting was predicted by computer simulation

using three criteria functions and a shrinkage porosity model. Three process
simulations were carried out for the porosity prediction. To validate the simulation,
three identical blocks were cast and were analyzed by computer tomography. The
results depicted that both simulations and porosity models are needed for reliable
porosity prediction. Porosity in aluminum sand casting alloy was analyzed using three
different simulation approaches and it was concluded that three porosity criteria
namely Niyama, dimensionless Niyama and BLJ and a fully-coupled shrinkage porosity
model well agrees with the experimental computer tomography results. The figure
below shows the simulation result.
Simulation results of Niyama Criteria for V rod
23
2.5 Casting Processes
2.5.1 Sand Casting
Sand Casting: Sand casting is used to make large parts (typically Iron, but also Bronze,
Brass, Aluminum). Molten metal is poured into a mold cavity formed out of sand
(natural or synthetic).
The various parts of sand casting are described below:
Pattern: The cavity in the sand is formed by using a pattern (duplicate of the real part),
typically made from wood, metal.
Core: is a sand shape inserted into the mold to produce the internal features of the
part such as holes or internal passages.
Riser: is an extra void created in the mold to contain excessive molten material. It
feeds the molten metal to the mold cavity as the molten metal solidifies and shrinks,
and thereby prevents voids in the main casting.
Cope & Drag: In a two-part mold of sand castings, the upper half, including the top
half of the pattern, flask, and core is called cope and the lower half is called drag.
Sprue: The vertical part of the gating system connected to the pouring cup
The diagram shows different parts of sand-casting methods
24
Advantages:
1) Low capital investment
2) Use of sand cores allows complex shapes to be cast
3) Large components can be produced
4) Suitable for small batch production
Disadvantages:
1) The process has a high unit cost, it is labor-intensive & time-consuming;
2) The sand-casting leaves bad surface finish, requires further processing;
3) Cannot make thin sections
4) Not suitable for mass production
Applications
engine blocks, gear blanks, crankshafts, brake drums, etc.
Cast Structure
The diagram shows a typical cast structure.
References: https://studylib.net/doc/10213089/fundamentals-of-metal-casting
2.5.2 Investment Casting

The investment casting process, also called the lost-wax process, was first used during
the period 3500-4000 B.C. The pattern is made of wax or plastic such as polystyrene.
25
The sequences involved in investment casting are shown in Figure. The pattern is
made by injecting molten wax or plastic into a metal die in the shape of the object.
The castings allow the production of components with accuracy, repeatability, and
versatility in a variety of metals and high-performance alloys.
Investment Casting of Turbine Blades

Turbine blades have a complex geometry and contain many areas of double
curvature. Therefore, the blades must be precisely manufactured by the precision
casting process of investment casting. Ceramic cores for the cooling channels are
positioned within a master mold pattern. Wax is then injected into the mold cavity to
produce a preform of the turbine blade. Next, the preform is coated with multiple
layers of ceramic, ultimately forming a thick casing around the preform. The assembly
is heated to melt out the wax and then dried to strengthen the ceramic. Finally, the
mold assembly is preheated prior to casting the turbine blade in the cavity.
Advantages of Investment Casting:

1. Many Intricate forms with undercuts can be cast.
2. A very smooth surface is obtained with no parting line.
3. Dimensional accuracy is good.
4. Certain un-machinable parts can be cast to preplanned shape
Disadvantages of Investment Casting:

1. This process is expensive, is usually limited to small casting, and presents some
difficulties where cores are involved.
2. Investment castings require very long production-cycle times versus other casting
processes.
3. This process is practically infeasible for high-volume manufacturing, due to its high
cost.
Applications:
1. Investment casting is used in the aerospace and power generation industries to
produce turbine blades with complex shapes or cooling systems.
26
2. It is widely used by firearms manufacturers to fabricate firearm receivers, triggers,
hammers, and other precision parts.
2.5.3 Die Casting

Die casting equipment was invented in 1838 for the purpose of producing movable
type for the printing industry. The first die casting-related patent was granted in 1849
for a small hand-operated machine for the purpose of mechanized printing type
production. In 1885, Otto Mergenthaler invented the Line type machine, an
automated type-casting device that became the prominent type of equipment in the
publishing industry. The die-casting machine, manufactured in Brooklyn, NY was the
first machine sold in the open market in North America. In 1966, General Motors
released the process.
2.5.4 Gravity Die Casting

Gravity die casting is a simple casting process that uses reusable metallic molds. This
type of casting is generally used for light alloys but can be used for steel and cast irons.
The process is most suited for simple shapes with some basic cores only. In this casting
process, the metal is poured into the cavity at atmospheric pressure only which is
unlike the pressure die casting where the pouring is done above atmospheric
pressure. The metallic molds consist of two halves which when combined gives the
required cavity.
Motor Block Casting
27
Advantages:
• Achieve good surface finish Due to the use of permanent mold
• The solidified casting can be easily removed by opening the halves
• Scrap metals can be recycled.
• Secondary machining operations can be reduced.
• Thinner sections can be manufactured
Disadvantages
• Only simple sections can be cast not complex shapes profile.
• Initial costs are high.
• Large scraps are produced
Applications
• Manufacture of automotive parts such as Engine bracket, torque rods, intake
pipes, cylinder heads, and brake calipers.
• To manufacture industrial equipment.
• Manufacture of parts for power transmission.
2.5.5 High Pressure Die Casting

This is a process for producing metal parts by forcing molten metal under high pressure
into reusable steel molds. This leads to a quick fill of the die, so the entire cavity fills before
any part of the casting solidifies. In this way, discontinuities are avoided. This creates the
problem of air entrapment because there is little time for the air to escape hence even in
a highly refined process there will still be some porosity in the center of the casting.
28
Advantages
• High-speed production can be achieved as the whole process is completely
automated.
• Very small thicknesses can be easily filled as the liquid metal is injected
under high pressure.
• Very good Mechanical properties & surface finish can be obtained.
Disadvantages
• Not suitable for all materials because of the limitations of the die materials
& the alloys used must have a low melting point.
• High porosity is common & heat treatment is difficult.
The main disadvantage of die casting is a very high capital cost. Both the casting
equipment required, and the dies and related components are very costly.
Applications
• *Instruments measuring device * Power & hand tools
• *Marines, pumps & compressors * Engines
2.5.6 Low-Pressure Die Casting
Low-pressure die casting uses a die which is filled from a pressurized crucible
underneath. The process is suited for thin casting rotationally symmetrical products
such as automobile wheels.
29
Advantages:
• Controlled mold filling and no turbulence
• Metal in the furnace is in a closed vessel under a protected atmosphere.
Less Hydrogen Absorption and other impurities
• Operator errors are minimized due to the automated process.
Disadvantages:
• Cannot be used for large castings as the casting machine capacity is limited.
• Prevents any heat treating or welding, because the heat causes the gas in
the pores to expand, which causes micro-cracks inside the part.
2.5.7 Centrifugal Casting (Industrial)

Centrifugal Casting mold is rotated at high speed so that the centrifugal force
distributes the molten metal at the outer region of the die cavity. Pipes, uniform
hollow section casting, etc. are made commercially by centrifugal casting method
without using any core. Centrifugal casting method can be classified as (i) True
centrifugal casting, (ii) Semi-centrifugal casting and (iii). Centrifuging
True centrifugal casting: In the True centrifugal casting process, mold is rotated about
a horizontal or vertical axis. Liquid metal is introduced into the mold through an
external source. The mold is rotated at a high speed and centrifugal force acts on the
molten metal which forces the liquid metal at the outer wall of the mold. The mold
rotates until the whole liquid metal solidifies. The slag particles containing the liquid
metal which are lighter than the liquid metal forced towards the central portion of
the casting. These slag particles are later removed by the machining process. Fig. 1a
shows the schematic diagram of the horizontal centrifugal casting machine. This
process is used to make hollow pipes, tubes, hollow bushes, etc. which are
axisymmetric with a concentric hole.
30
True Horizontal Centrifugal Casting Machine
True Centrifugal Casting Machine
Reference : https://www.open.edu/openlearn/science-maths-technology/engineering-
technology/manupedia/centrifugal-casting
Horizontal Centrifugal Force (F) = mV2/R, Where m= mass, V = velocity and R =

External Radius
The G Factor (GF) = Centrifugal Force / weight (mg)
GF = mV2/R/mg = V2/Rg
V (Velocity) = 2π RN/60 = π RN/30, N= RPM
GF = R/g (πN/30)2 N = (30/ π) [g (GF)/R]1/2
If G factor is too low in centrifugal casting, then the liquid metal will not be forced
against the mold wall during the upper half of the circular path but will rain inside the
cavity i.e., slipping occurs between the mold wall and the molten metal. This means
31
that rotational speed is less than the molten metal. GF should be around 60-80 for
successful casting.
Vertical Centrifugal Casting: The vertical centrifugal casting machine is shown in Fig.
1b.The effect of gravity acting on the liquid metal causes the casting wall to be thicker
at the base than at the top (Fig. 1c). The difference in inside radius between top and
bottom is related to the speed of rotation.
30 2𝑔𝐿
𝑁= √𝑅𝑡
̅̅̅̅̅̅̅̅̅̅̅
2 −𝑅 2
𝜋 𝑏
L = Vertical length of the casting, Rt = Inside radius at the top, Rb =Inside radius at the
bottom
Semi-Centrifugal Casting: In this process, the centrifugal force is used to produce solid
casting rather than tubular parts. The rotational speed is set in such a way that the G
factor would be around 15. The density of metal is more at the outer than the center.
Semi Centrifugal Casting Method
Reference : https://docgo.net/embed/centrifugal-casting-velocidad
Semi centrifugal casting process is used to cast large size axisymmetric components.
In this process, mold is placed horizontally and allowed to rotate along the vertical
axis as shown in Fig. 1d. A core is inserted at the center which is used to cast hollow
32
section components. When the mold is rotated, the outer portion of the mold fill by
purely centrifugal action and as the liquid metal approaches the center, the
centrifugal component decreases, and the gravity component increases. Thus, a core
is inserted at the center to make a hollow cavity at the center without centrifugal
force. In this process centrifugal force is used for a uniform filling of axisymmetric
parts. Gear blanks, flywheel, etc. are made by this process.
Centrifuge Casting: In this process, there are several mold cavities connected with a
central sprue with gates. This process uses higher metal pressure during
solidification. It is used to cast shapes which are not axisymmetric. This process is
suitable for making small objects.
Reference:
https://pdfs.semanticscholar.org/e20a/b58a7f24fd5a3a695bdbfd4a119b2ae6ec61.pdf
2.6 Casting Components

2.6.1 Core Plug
“Sand cores are used to form the internal cavities when for example the engine block
or cylinder head(s) is cast. These cavities are usually the coolant passages. Holes are
designed into the casting to support internal sand forms and to facilitate the removal of
the sand after the casting has cooled. Core plugs are usually thin metal cups press-
fitted into the casting holes but may be made of rubber or other materials. In some high-
performance engines, the core plugs are large-diameter cast metal threaded pipe plugs.”
(Monroe, 1996, p111)
2.6.2 Riser Casting /Feeder

A riser is a reservoir for supplying molten metal to the casting cavity to compensate
for the shrinkage (volumetric contraction) taking place during the solidification
process. If we consider the elements of casting, we come across seven kinds of
elements namely (i) pouring cup, (ii) Sprue (iii) Sprue well (iv) runner (v) Gating system
33
(vi) casting and (vii) Riser. Figure below shows a typical casting system with all seven
elements.
A typical casting system showing seven elements

Reference : https://www.slideshare.net/chicharitobale/c2-casting
The Sprue of the Gating System: The vertical channel through which metal enters is
known as sprue. The aspiration of mold gases is likely to occur through a sprue. The
aspiration can be minimized by tapering the sprue so that the metal does not pull
gases from the mold wall as it moves downwards.
For the free-falling of liquid metal, the velocity of liquid metal (v) increases with the
height of the sprue.
V = (2gh) where h is the height of sprue.
Let A1=Cross sectional area of entrance of sprue
A2 = Cross-sectional area of exit of sprue
h1 = pouring basin height
h2 = Sprue + pouring basin height.
So, the condition for no aspiration is A1 / A2 >=  (h2/h1)
34
Figure below shows the two conditions of liquid metal flow through the sprue. In
condition (i) straight-sided sprue in which there is every possibility for aspiration of
gases. In condition (ii), the sprue is tapered and there is no aspiration of gases.
i ii
Figure above shows the schematic diagram of the condition (i) with straight sided
sprue and condition (ii) with tapered sprue.
Reference : https://www.sciencedirect.com/topics/engineering/casting-process
Riser: A riser is made above the cope portion and can supply liquid metal to fill the
shrinkage cavity resulting due to volumetric contraction. The riser must be kept open
to the atmosphere to attain positive pressure and placed in such a location to supply
liquid metal in all the sections of the casting. The shape of the riser is cylindrical, and
the volume of the riser would be enough to supply enough liquid metal. Usually, the
volume of the riser is three times the contraction volume. There are two types of
risers, one is open riser (top riser) and the other is a blind riser. In open riser, the top
portion of the riser is open to atmosphere, hence the gravity and atmospheric
pressure causes the liquid metal to flow into the solidifying casting. The blind riser is
completely enclosed in the mold cavity and not exposed to the atmosphere. The liquid
metal cools slowly and retains a liquid state for a longer time and feeds the solidifying
casting by gravity only.
35
Side Riser
Mold
Schematic diagram showing open riser and blind riser.
Riser design is very important because of the following reasons:
• An undersized riser could lead to shrinkage defects and ultimately a rejection

of casting
• An oversized riser requires excess molten metal. Needs more power/fuel
consumption for melting practice
Necessary and enough conditions for riser design
• Necessary Condition: Vr > 3 Vsc
Vr= Volume of Riser and Vsc= Volume of Shrinkage
• Sufficient Condition triser > tc
triser , Solidification time of riser metal > tc , Solidification Time of Casting
• Location of Riser: Easy flow of liquid metal to the casting

• The shape of Riser: Minimum surface area.
36
Riser Efficiency: The riser efficiency can be improved through the following:
• Use of insulating materials around the riser

• Use of chills.
• Use of Exothermic materials in the riser so that it provides heat to maintain
the metal in a liquid state for more time.
2.6.3 Insulating or Exothermic Sleeve
Insulating or exothermic sleeves are used to increase the yield in foundry practice.
Each of the sleeve manufacturers provides a large variety of sleeves in different
sizes. An exothermic reaction is a chemical reaction that is accompanied by the
release of heat. It gives out energy to its surroundings. The energy needed for the
reaction to occur is less than the total energy released. During the pouring of mold,
an exothermic reaction sets in as molten metal fills an exothermic sleeve riser. It is
possible to reduce the riser size considerably as compared to sand riser system as the
exothermic reaction helps in maintaining the riser metal temperature over an
extended period of time.
Yield: Use of Exothermic sleeves enables improving the yield by more than 30%
37
Benefits:
• Permits use of substantially reduced riser size without compromising on
quality.
• Cost savings due to high foundry yields.
• Significant saving in energy and costly foundry inputs due to the

minimization of feed metal.
• Higher productivity.
2.6.4 Overflow Risers (Cavity/Passages)
Overflows are cavities and passages in the die which act as vents for air to escape and
traps for excess metal flow. Overflows reduce/prevent porosity in the diecasting and
promote complete metal fill into the far sections of the cavity.
Overflow
38
2.6.5 Casting Coolers
The casting exposed by the Shakeout is too hot to handle. Thus, they are
passed through a Casting Cooler to reduce their temperature. This can be a
standard Vibrating Conveyor with a top cover that induces cool air to flow over
the hot castings and exhaust out of the hooded cover.
Casting cooler
2.7 Pouring Techniques

Crucible melting is one of the oldest and simplest processes of melting
furnaces. It is the simplest furnace used for melting of metals and alloys in
foundry practices. The furnaces use a crucible made of graphite + silicon
carbide + clay + resin etc. The heating fuel used in crucible melting is coke, oil
or gas. The charge (metal /alloy to be melted) is heated via conduction of heat
through the walls of the crucible. The crucible is placed in a chamber with the
walls made of insulating ceramics. Crucible melting is commonly used where
small batches of low melting point alloy are required.
39
Crucible Furnace
Types of Crucible Furnaces

There are three types of crucible furnaces with coke/oil/gas and the classification of
crucible furnaces is based on the method used for removal of the metal from the
crucible. The first category of crucible furnace is Lift-out crucible. In this type, the
crucible is lifted out and then poured it into the mold. The second category of crucible
furnace is known as Stationary pot in which the molten metal is ladled out of the mold.
The third category of crucible furnace is tilting –pot furnace in which a mechanically
tilting mechanism is used to take out the liquid metal.
Lift-out Crucible Stationary Pot Tilting –pot furnace

Typical image of Crucible Furnace
Reference: http://www.anthonydpmann.com/types-of-crucible-furnace/
40
The advantages of crucible furnaces are, (i) Low installation cost, (ii) low melting
losses, (iii) Uniform heating of the charge (iv) Ease of operation (v) Continuous
operation.
However, in recent times the use of crucible furnaces is declined and electric
induction melting furnaces which offer precise melting temperature and easy control
of the chemistry of alloys is favored.
Application of Crucible Furnace: Crucible furnace is useful for melting non-ferrous

metals and alloys.
Crucible Pouring in Inspire Cast
Crucible poring
Crucible/tilt pouring
41
2.8 Molding
Varieties of molding sand

available in the module
Casting is a manufacturing process in which a liquid material is usually poured into

a mold, which contains a hollow cavity of the desired shape, and then allowed to
solidify. The solidified part is also known as a casting, which is ejected or broken out
of the mold to complete the process. Basically, molding is the process by which we
take an object and create an impression of it in some sort of material. Generally,
initially soft material is poured or spread around the object and allowed to harden or
set, creating a negative imprint of the object. Moldings can be made in either one
piece or multiple pieces. While the type of molding material used depends on the size
and shape of that object, some popular options include plaster and silicon.
References:
a) Monroe, T, 1996, Engine builder's handbook: inspection, machining,
reconditioning, valvetrain assembly, blueprinting, degreeing cams, tools,
engine assembly, HP Books, p. 111,
b) K.G. Swift, 2003.,J.D. Booker, in Process Selection (Second Edition)
c) K.G. Swift, 2013, J.D. Booker, in Manufacturing Process Selection Handbook
42
3. Defects on Casting
During the casting process, the liquid melt is solidified in a mold (sand mold or
permanent mold) to achieve the shape of the desired components. During
solidification of the melt, defects may arise due to irregularities in either casting
materials or casting process. Some of these defects may be tolerated, repaired or else
would be rejected. The casting defects arise due to many reasons and are classified
as below
1. Due to the evolution of gases
2. Due to the pouring of the melt into the mold
3. Due to Metallurgical Defects
4. Caused by molding materials
5. Due to Shrinkage
6. Due to other factors
All the above-mentioned defects are described in detail in the sections to follow.
3.1 Casting Defects Due to the Evolution of Gases

The solubility of gases in liquid metals and alloys is much higher as compared to the
lower temperature. Because of this reason liquid metal is treated with gas purging
and addition of degasser to remove the dissolved gases. On the contrary, the
dissolved gases, if not removed, results in defects in solid casting. Defects due to
entrapped gasses are generally known as blowholes, pinhole porosity, rat tails, blister,
etc.
3.1.1 Blow Holes

The essential causes of blow holes casting defects are (i) Excess moisture in the mold
(usually 3-5% moisture) (ii) slag in the metal reacts with carbon in the metal and
43
liberates CO which entrapped in solidified metal and (iii) Iron Oxide in the mold wall
react with carbon in the metal which evolve CO gas.
These defects can be minimized by the following ways: (i) avoid excess moisture in
molding sand (ii)avoid excessive compaction of the
mold, (iii) avoid using rusted chills and chapters, (iv) Provide vent holes, (v) Removal
of slag from the liquid metal. When the blow holes casting defects are found inside
the casting it is called Blow Holes. On the other case when the defects are found on
the surface of the casting, it is called Open Blows. Below Figures show the typical
photographs of Blow Holes and Open Blows respectively.
The Shape of the defects may be spherical, Flattened or Elongated cavities and the
size in the range of 0.5-3 mm.
Reference : http://www.iron-foundry.com/casting-defects-pictures.html
3.1.2 Pin Hole Porosity
A Large number of tiny holes of a size similar to pinheads appear on the surface of the
casting. The main causes of pinhole porosity are the absorption of gases like
hydrogen, oxygen, etc. by the molten metal inside the melting furnace and molds.
During solidification, the temperature gets reduced and liberates the dissolved gases.
Copper, Gold, silver usually absorb oxygen and Palladium, platinum, Aluminum,
absorb hydrogen resulting in pinhole porosity. The dissolved gases may be removed
from the molten metal by using one of the melting practices such as (i) vacuum
Melting practices (ii) vacuum Degassing (iii) avoid very high pouring temperature. A
typical photograph of pin-hole porosity is shown in the following figure
44
Photograph of typical pinhole porosity (this is due
to high moisture content in the sand)
Reference :
https://maritime.org/doc/foundry/part3.htm
3.1.3 Rat Tails or Vains Defects
It is an irregular depression on the surface of the castings like rat a tail impression.
The causes of such kind of depression are essentially due to the following reasons: (a)
as the molten metal is poured in a sand mold, the moisture in the molding sand
evaporates and is converted into steam. (b) When the mold cools down the steam
condenses and forms a thin layer of moisture between the mold surface and the
solidified metal. (c) As the hot sand expands, the wet layer of steam shears to allow
the expansion. The small ridge of sand that extends into the mold cavity can create a
line on the surface (Depression on the surface) which looks similar to a Rat`s tail. Fig.
below shows a typical photograph of rat tails. To minimize the defects, care should be
taken to minimize mold wall movement and additives like wood flour may be added
with sand to reduce sand expansion.
Long, shallow, angular depression in the surface of the flat casting looks like a rat tail
Reference : https://maritime.org/doc/foundry/part3.htm
45
3.1.4 Dispersed Shrinkage
Dispersed shrinkage is a kind of defect that looks like cavities dispersed throughout
the casting. It is caused due to excess moisture content in the molding sand and
large pouring temperature of the metal. To minimize the defects appropriate
moisture content and pouring temperature should be used.
Components show dispersed shrinkage cavities (Arrow marked)

Reference : https://www.giessereilexikon.com/en/foundry-
lexicon/Encyclopedia/show/dispersed-shrinkage-
3866/?cHash=9bec6921187bcf58644b31364b458157
3.1.5 Blister
These kinds of defects show up as a swelling on the casting surface. The size of the
defects is found in the range of 1 to 20 mm in diameter and 0.5 to 5 mm in height. If
they appear on a visible surface of the casting, it is rejected and there is no scope of
repairing. Blisters are caused when gas is trapped inside the casting at the time the
cavity is filled with molten metal. The most likely source of the gas is the air which was
initially present in the cavity, runners and shot sleeve in the die casting process. Figure
shows a typical blister formation on the surface of the casting.
When the plunger comes to the end of its stroke, it compresses the metal, and any
gas trapped inside it, to very high pressure – typically 20 to 70 MPa. This causes the
gas to be compressed to very small bubbles, trapped on the casting surface. Tiny gas
46
bubbles are called porosities, but larger gas bubbles are called blowholes or blisters.
Such defects can be caused by air entrained in the melt, steam or smoke from the
casting sand, or other gasses from the melt or mold.
Formation of Blisters on the Casting Surface
Reference : https://www.cwmdiecast.com/blog/2015/08/18/porosity-at-a-glance/
3.2 Casting Defects Due to Pouring of Melt

3.2.1 Mis-Run
In die casting the most common defects are misrun. This defect is caused by the
following reasons: (a) cold dies (b) low metal temperature (c) dirty metal (d) lack of
venting, etc. This defect is caused due to incomplete cavity filling and the reasons
can be: - (i) inadequate metal supply, (ii) too-low mold or melt temperature, (iii)
improperly designed gates, or length to thickness ratio of the casting is too large.
When molten metal is flowing from one side in a thin section, it may lose sufficient
heat resulting in loss of its fluidity, such that the leading edge of the stream may
freeze before it reaches the end of the cavity. The figure below shows a typical
photograph of a misrun. The defects formed due to misrun is shown by the arrow
mark.
47
The photograph shows misrun defects due to improper flow of metals.
Reference : https://www.ijert.org/research/causes-of-casting-defects-with-remedies-
IJERTV4IS110511.pdf
3.2.2 Cold Shut
A cold shut is caused, when two streams while meeting in the mold cavity, do not fuse
together properly thus forming a discontinuity in the casting. When the molten metal
is poured into the mold cavity through the more-than-one gate, multiple liquid fronts
will have to flow together and form one solid. If the flowing metal fronts are too cool,
they may not flow together but will leave a seam in the part. Such a seam is called a
cold shut. The figure below shows the casting defects due to Cold shut.
(a)
48
(b)
(a) The photograph shows cold shut defects due to insufficient flow of metals (b)
Showing the flow of liquid metal in opposite direction (arrow marked) but due to
lower temperature could not fuse together.
Reference : https://www.intouch-quality.com/blog/21-casting-defects-and-how-to-
prevent-them-in-your-products
3.2.3 Elephant Skin
Elephant skin is a surface defect and this kind of surface defects form due to the
presence of magnesium silicate contamination in the melt. This kind of defect is
caused when separate streams meet together, and the surface films will not allow
complete fusion and results in the formation of an elephant skin-like surface.
Photograph below shows the surface defects of casting resemble elephant skin. This
kind of defects can be avoided by removal of slag inclusions from the melt.
The photograph shows a typical elephant skin type defect.
49
3.3 Inclusions
3.3.1 Solid Inclusions
The formation of solid inclusions is generally caused due to turbulence in the molten
metal giving rise to sand or slag inclusions. Sand inclusions are caused by bulk
turbulence in gating channels or mold cavity whereas slag inclusions are due to
surface turbulence in the path of molten metal.
Bulk turbulence - It is the ratio of inertia to viscous pressure in a fluid and is expressed
by the equation - Reynolds Number (Re) = ρ v l / µ. The flow is usually turbulent when
Re is more than in 2000.
Ρ = Density of metal, v = velocity of pouring melt, l = Characteristic Length, µ =

Viscosity of melt.
Surface turbulence - It is the ratio of inertia to surface tension pressure in a fluid and
is expressed by the equation We(Weber No.)= ρv2l/σ. The flow is turbulent when We
number is more than 100. Here σ is the surface tension of the melt. Figure (a) and (b)
show the inclusion content in the casting. This kind of hard inclusion results in crack
nucleation and propagation. Inclusions particles are shown by arrow marks.
(a) Slag Inclusions (b) Sand Inclusions
(a) the photograph shows the slag inclusions in the metal matrix (arrow marked) (b)
Shows sand inclusions in the metal matrix (Arrow Marked)
50
Inclusions content can be reduced by using the correct grade of molding sand and
proper skimming to remove impurities. The use of filters is used in most of the casting
industries to remove the inclusions. Figure below shows typical ceramic filters used
for cleaning of liquid metal and remove the inclusions.
The figure depicts the ceramic filters for removing the inclusion content in liquid metal
(a), (b) and (c) are the three different arrangements for the filtering of inclusions in
liquid metal.
3.4 Casting Defects Due to Metallurgical Factors

3.4.1 Hot Tears
Hot tears are quite a common type of casting defect due to differential contraction of
the casting during solidification. It may be caused when the casting could not undergo
shrinkage freely during solidification due to complex casting design. The presence of
sulfur in steel also promotes hot tearing. It may also be noted that long freezing range
and decrease in the quantity of eutectic influence hot tearing. Example: Al-Sn alloy.
Al-10 Sn alloy is more susceptible to hot tearing. The figure below depicts the hot tear
shown by the arrow mark.
51
The hot tearing problem in casting can be suppressed by using an exothermic pad,
control of Composition for example addition of Mn in steel minimize sulfur content,
use of grain refiners namely Al-Ti, Al-B, etc. refine the grains and reduce the hot
tearing. It was observed that the addition of Ni reduces the hot tear by locking
neighboring grains.
Hot tear at the corner junction shown by the arrow mark.
Reference : https://www.ecodiecasting.com/die-casting-defects-causes-and-
troubleshooting/
3.5 Casting Defects Caused by Molding Materials

Molding materials generally consist of molding sand, clay, and moisture. A little
amount of coal and or wood dust is also added for the easy breaking of the mold
material.
3.5.1 Scab
Scab is a type of defect generally found on the surface of the casting. Scabs are rough,
irregular projections on the surface of castings containing embedded sand. Scabs
occur formed when a portion on the face of mold or core lifts and the metal flows
underneath in a thin layer. They are caused by using too fine sand grains or using sand
of low permeability or moisture content. A scab may also be caused by uneven mold
ramming or by intense local overheating. Figure below shows the scab defect shown
by the red circle mark. Scabs can be reduced by mixing additives like sea-coal, wood
52
flour or dextrin in the sand, providing uniform ramming and pouring with a correct
velocity of liquid metal.
The photograph shows a typical scab formation on the surface of the casting.
Reference : https://www.giessereilexikon.com/en/foundry-
lexicon/Encyclopedia/show/scab-4013/?cHash=a0a63600b9e09b473829e740b17ebf36
3.5.2 Metal
Metal penetration is an unwanted projection of metal above the casting. It is caused

mainly when the sand grains used are coarse in size and of insufficient composition.
It may also be caused due to metal poured at a very high temperature. The liquid
metal can enter the spaces between the sand grains up to some distance. Such sand
gets tightly wedged in the metal and is difficult to remove afterward. Figure below
shows the metal penetration defects by the arrow mark. This kind of defects can be
minimized by using fine sand grains, reduce casting temperature, apply enough
compaction of mold and use additives in the molding sand.
53
A typical photograph shows the penetration defects caused by metal penetration.
Reference : https://www.foundrymag.com/feature/new-coating-additive-concepts-
defect-and-residue-free-castings
3.5.3 Fusion
When the molding sand does not have enough refractoriness or the metal is poured
at very high temperature or the facing sand is of poor quality, the sand may melt and
fuse with the casting surface. This makes it difficult to clean the castings and gives
them a rough glossy appearance. This kind of defects can be avoided by using sand
of enough refractoriness and pouring of liquid metal at a suitable temperature not
very high. Figure below shows the flush defects. The fused material can be seen by
arrow marks and also in red circle.
Fusion molding sand on the casting surface.
54
3.5.4 Flash
Flash is a casting defect caused due to improper compaction of molding sand along
the parting line. Due to this reason, a minor gap will exist between cope and drag, and
liquid metal flew away through the gap. This will form a flash defect. Figure shows the
typical flash defects. This is simply a projected portion out of the component. This
type of defects can be alleviated by leveling molding sand properly along the parting
line.
Photograph showing a typical defect of Flash.
troubleshooting/
55
3.5.5 Run Out
It has been observed that in some instances molten metal leaks out of the mold during
pouring and casting practices. This is caused by the hydrostatic pressure of the liquid
metals which lifts the cope due to insufficient weight on the cope. Due to this
pressure, liquid metal will flow along the parting line. Figure shows the runout
defects i.e.; extra metal comes out from the parting line. This kind of problem can be
minimized by modifying the molding system by putting some weight on the cope.
(a) Showing run out defects (b) Putting weight on the cope portion
(a) Showing the run-out defects and (b) Putting loads on the cope so that cope
portion should not move up due to pressure.
Reference : https://www.backyardmetalcasting.com/defects.html
3.5.6 Lug
Lug is one of the casting defects that appears when some of the portions of the cast
contour are broken off in the mold area during the withdrawal of the pattern. i.e., the
mechanical breaking of mold. Hence this kind of defects can be minimized by repairing
the mold and checking the mold before the pouring of liquid metal. Figure below
shows a photograph of casting defects lug.
56
A photograph depicting broken edges due to broken mold corners (wheel lug)
Reference : http://www.metallurgist.com/lug-nut-failure.html
3.5.7 Shrinkage Cavity
Shrinkage cavity is caused due to the following reasons:
• The insufficient size of riser- If the riser volume is less than shrinkage volume
then shrinkage defect will arise.
• Improper position of the riser: If the riser is positioned improperly, then also
shrinkage defects will form.
• Pre-mature freezing of liquid metal in the riser
• The abrupt change in casting design
The figure above depicts the typical shrinkage defects.

Reference : https://www.backyardmetalcasting.com/defects.html
57
The shrinkage defects can be minimized by the following techniques:
• Sufficiently large riser dimensions

• Ensure Directional Solidification
Use of Exothermic Compound /materials e.g., Ni, Co, Cu, Mn, Fe, etc.
• 4Fe2O3 + 8Al = 4 Al2O3 +8Fe + Heat (4500 0C)

• Use of insulating coatings
3.6 Casting Defects Caused by Other Factors

3.6.1 Mismatch
Mismatch is a casting defect caused due to the improper placing of cope and drag
parts of the casting. This may happen due to lose box pins, inaccurate pattern dowel
pins or carelessness in placing the cope on the drag. Figure shows a typical photograph
of a mismatch of cope and drag. The upper portion i.e., Cope portion is shifted
towards right.
Photograph showing typical Mismatch defects.
troubleshooting/
3.6.2 Hot Cracking
Hot Cracking is a casting defect that occurs due to the non-uniform cooling of the
casting. It may also occur during knocking out of the casting from the mold and during
the heat treatment cycle. Figure below shows a typical photograph of hot cracking.
58
The crack propagation is shown by arrow marks. This kind of defect occurs due to
uneven cooling and differential contraction. To minimize the hot cracking defects one
should use chills, filters, and avoid rough handling.
Photograph showing hot cracking in valve casting.
https://www.ecodiecasting.com/die-casting-defects-causes-and-troubleshooting/
59
4. Inspire Cast Modules
Altair Inspire Cast Modules are Fast, Easy, Accurate & Affordable, using Altair
Inspire Cast for casting simulation allows us to quickly perform iterative
improvements on our projects, reducing the time necessary to achieve an optimal
casting process. This reduction in design time is reflected in the reduction of tooling
development costs.
Altair Inspire Cast was developed with its end-users in mind. We strive to make casting
simulation as easy as possible by using ‘foundryman’s language’ in our software. Every
word in the interface comes from the casting process world. Not only is the software
incredibly easy to use, but it is also highly accurate and powerful. Get started with
Altair Inspire Cast today to further investigate and explore your casting process with
just a few clicks, it is much easier and time-saving.
Casting as a manufacturing process to make complex shapes of different materials in

mass production may experience many different defects such as shrinkage porosity,
sink, cavity, and incomplete filling. A well-designed feeding system is important to
ensure better quality of castings. The design of the feeding system also involves the
decision about the correct location of risers and the number of risers to be used.
Generally, the gating system controls the velocity of molten metal that affects
turbulence and flowability of casting. Solidification of metals stands as a marvel of
ultimate significance for metallurgists, casting engineers and physicists which
hampers the quality of castings, material yield and cycle time. Casting defects are
decreased through casting simulation software and an intellectual feeding technique.
Altair Inspire Cast is a casting simulation software which can simulate thermal changes
and heat transfer in the solidification process of a casting and much more. The
simulation software offers functions to help guide a user in producing gating and riser
designs and have functions that produce visual outputs showing possible problem
areas, Microporosity, and defects which may occur in a casting. It can help shorten
60
the lead time and reduce the loss in the trial casting stage prior to manufacturing.
Now we will discuss simulating each casting process discussed so far using Inspire Cast
61
5 Gravity Casting (GDC)
5.1 Introduction to Gravity Casting
Gravity Casting is the pouring of metals under gravity and is generally an extremely
damaging process and creates defects in the casting which limit properties and
performance, but the damage can be limited to some extent by extreme care. In
contrast, counter-gravity casting has the potential to fill molds without the production
of any defects. Historically problems which have impaired success with gravity casting
were analyzed and Counter-gravity is recommended as the process for the future.
Gravity casting flow covers both the kinematics of the fluid propagation in the mold
geometry and assessment of the test fluid physical properties. The mold cavity fills
with no force other than gravity, the filling can be controlled by tilting the die.
Undercuts and cavities can be incorporated into the component with the use of sand
cores. This process gives a better surface finish than sand casting as well as better
mechanical properties, both due to rapid solidification.
5.2 Defining Ingate Systems

The gating system refers to all those elements which are concerned with the flow of
molten metal from ladle to mold basin cavity. The various elements that come under
the gating system are:
• Pouring basin/cup
• Sprue base wall
• Runner
• Runner extension
• In-gate
• Sprue well
• Down Sprue
62
Pouring Basin /
cup
Down sprue
base wall
Multiple In-
gates
Runner
extension
Sprue Base cup
5.3 Gravity Casting Simulation Set-Up

Altair’s Inspire Cast has five basic steps in setting up a gravity casting simulation.
• Defining ingates
• Defining the parameters
• Run Analyze
• Cast final part
Defining ingates Defining parameters Run Analyze
Components
• Core
• Chiller
63
• Riser
• Sleeves
• Overflow
• Mold
• Cooler
• Filter
• Short Sleeve
• Crucible
Material
Selection
Click on the Cast part
5.4 Selection of Material

Varieties of standard materials are available in Altair Inspire Cast. The properties of
these materials can be edited. Clicking the icon material viewer,
pops the material database, also using my materials one can add new customized
materials.
64
Customized material
5.5 Pre-Process Parameters (Components)/Basic

Set-Up
Basic Setup
• Initial velocity
By clicking in preprocess parameter one can set the initial velocity
65
• Filling time
Filling Time is nothing, but the time required to cast or mold a product. The efficiency
of the casting is normally affected by two scenarios.
Slow Filling: If the velocity of the fill is very slow, it leads to cold shuts and misruns.
The slow filling is avoided because of the early freezing in thin sections before the
complete filling.
Fast Filling: The fast filling is governed by the onset of surface instability. The
optimal filing time lies in-between this fast & slow filling. It also depends on the
following factors like:
• Cast metal
• Weight
• Pouring temperature
• Minimum section thickness.
66
Gravity Process
• Constant liquid level on a sprue
• filling time
• flow rate
Other parameters
• average thickness
• element size
• speed and accuracy
• type of analysis
Advanced
• Component Mesh factor
• Element size ( will be only for a part)
5.7 Tutorial: Brake Caliper

Brake Caliper Casting
The filling requirements of gravity casting are like those of other processes: avoid
turbulence during filling and have a homogeneous liquid advancing front. If possible,
fill the component from the bottom to the top to avoid turbulence and the free fall
of liquid.
Ingate for gravity casting
67
Use the Add/Edit ingate option to design your virtual ingates.
Ingate
Once you have positioned the ingates, you need to design the filling system (sprue).
Inspire Cast is an excellent tool for analyzing the sprue to prevent turbulence, which
creates air bubbles that travel through the mold.
Position of ingate
Ingate
The initial setup process for gravity casting

There are different options for setting up gravity casting in Inspire Cast:
68
Using Basic Parameters
• Initial Velocity: defining the velocity at the predefined ingate. In gravity
casting, velocities tend to be around 0.5–1.0 m/s. If you don’t know what
the velocity is at the ingate, use a similar value and then check solidification
at filling results to decide if the selected velocity is correct (no early
solidification would occur).
• Filling Time: use this option if you have calculated the exact filling time
required for your process. Units must be in seconds. Inspire Cast internally
converts the filling time to velocity as input.
𝑣
𝐹𝑡 =
𝐴𝑖𝑛𝑔𝑎𝑡𝑒 ⋅ 𝜈
You can use the Advanced Ingate option to avoid designing

ingates in CAD and save time.
Gravity Process
• Use the Gravity option for gravity sand or die casting.
• Gravity sand casting has few limits on size, shape, and weight, with low
pattern and material costs.
69
• It is generally less accurate than die casting and has a low production rate
due to the destruction of the molds.
• Gravity sand casting generally uses ferrous metals such as stainless steel,
carbon steel, cast iron…
• Gravity die casting is a type of permanent mold casting generally used to
produce small, simple metal parts such as gears, pistons, and wheels.
• It is like gravity sand casting but with a permanent mold, making it a better
choice for high production volumes.
• Gravity die casting generally uses non-ferrous metals such as aluminum,
magnesium, and copper alloys, although iron and steel parts can also be cast
using graphite die molds.
1. Specify Basic Parameters

• Filling Time, Spoon Height or Flow Rate
2. Process Parameters Options
• Filling Time: to calculate the exact filling time required for
your process. Inspire Cast internally converts the filling time
to velocity as input.
70
𝑣
𝐹𝑡 =
𝐴𝑖𝑛𝑔𝑎𝑡𝑒 ⋅ 𝜈
• Spoon Height: the flow rate depends on the area defined as the ingate. You
can also choose the ladle pouring height (mm) with respect to the mold.
Spoon height is the distance between the ladle and the mold when the
liquid is being poured. If you don’t know this value, use a value around 10–
30 mm.
𝑣2
𝐻=
2𝑔
• Flow Rate: is the poured metal volume in kg divided by the filling time in
seconds. This parameter can be calculated when using an auto-pour ladle,
bottom-pour ladle, or stop-and-rod ladle, etc.
Q=A ingate. V. ρ
Example Simulation Gravity Casting of Brake Calipers

Final Design:
Original Design Inspire Cast Results Free of Defects!
Technical Background: Gravity Sand Casting Process

Sand casting is one of the most common casting processes, as it can be used to
produce a variety of parts from simple gears and pulleys to complex components such
as automobile engines. The process uses an expendable sand mold to form metal
parts called castings, which can be made of nearly any alloy. The metal is melted in a
71
furnace and then poured into the cavity of the sand mold. Once the casting is
solidified, it is removed from the sand mold. Gravity sand casting has few limits on
size, shape, and weight, with low pattern and material costs. However, it is generally
less accurate than die casting.
Step 1
a) Start Inspire Cast.
b) Click on New Model.
c) Click on Open Model.
d) Browse to and select file Exercise5-gravity.x_b
Step 2: Let’s select the Casting Part.

a) Click on Cast Part.
b) Select the geometry.
c) Change the Casting Material to Steel and select the 14903 alloy
d) Click on the Material Property viewer to see the Material Properties.
e) Click on the right mouse button to exit the context and confirm the
selection.
72
Note: Gravity Die Casting and Investment Casting processes are also available in
Inspire Cast. The only difference is the mold settings selection (Steel mold material
for gravity die Casting and Shell thickness for Investment casting).
Step 3
a) Click on the Gravity button to move the part with respect to its
position in the mold.
b) Click on the second option of the new Windows.
c) Click on the bottom Surface.
d) The part will be automatically positioned with the Gravity
perpendicular to the selected Surface.
73
Step 4
a) Click on Add/Edit Gate to create an inlet.
b) Click on the top Surface shown in the right picture to create a gate.
c) Change the radius of the inlet area to 6mm.
d) The inlet will automatically change to the new shape.
Note: Inlet (gate) is the area where the material enters the component.
Step 5
a) Click on the Move button.
b) Click on the top arrow to pull the inlet until it reaches 8mm.
c) Click and drag the rotation axis on Y-axis until 20º to tilt the inlet.
d) Click on the right mouse button to exit the context and confirm.
74
Step 6
a) Click on the components button to open the components selection
bar.
b) Select the Core Component.
c) Core candidate surfaces will be highlighted.
d) Click on the Core Surface to automatically create the core volume
and select the core material and temperature.
e) Click on the right mouse button to exit the context and confirm the
selection.
75
Step 7
a) Now Click on the Mold button from the component’s selection bar.
b) Select “Green Sand” as a Mold Material and 20ºC.
Step 8
a) Click on the Basic Setup button to select to enter the simulation
parameters.
b) Enter 1m/s as initial velocity. This will be the velocity at the inlet
during all the filling of the mold cavity.
76
Step 9
a) Click on Run Analysis to set up the calculation parameters.
b) Select Filling Analysis.
c) Enter an element size of 3mm.
d) Click on the Run button to start the calculation.
Step 10
a) Click on View Now to open the simulation results.
b) It’s is also possible to open the simulation results once the
calculation has finished by clicking on the green flag.
77
Step 11
a) Click on Temperature results.
b) Click the Play button to start the animation
Note 1: We can observe how the liquid is falling from top to the bottom and this can
result in turbulence.
Note 2: Temperature results will show temperature evolution during the filling, but
it is also very useful to analyze the behavior of the fluid entering into the mold.
Note 3: Switch off the Core component in Legend Manager to view the correct
colormap
78
Step 12
a) Click on Filling time result.
b) Click the Play button to start the animation.
Here we can also see the differences in time to fill right and left regions
Note1: Here we can also see the differences in time to fill right and left regions so let’s
go back and change the inlet position to avoid this issue.
Note2: Filling time shows the time it takes the material to reach different areas within
the part, based on a color legend. Filling time is also useful to analyze the behavior of
the liquid entering the mold
Step 13
a) Click on Add/Edit Gate.

b) The previously created inlet will be highlighted.
c) Click on the Delete button of the keyboard to delete the inlet.
79
d) Let’s create the inlet at the bottom of the geometry. Click on the
center of the surface shown at the right image. Inlet will be
automatically created
e)
Note: In case the inlet is not automatically highlighted, just select it manually.
Step 14

b) Select Filling Analysis.
80
Click on the Run button to start the calculation
Step 15
81
Step 16
a) Click on Temperature results.
b) Click the Play button to start the animation
With Core
Without Core
Note: Now we can see how the liquid is entering the mold much more stable, the
fluid rises homogeneously and without turbulence.
82
Step 17
a) Click on Mold Erosion result.
b) Set the minimum value to 0.5 m/s.
Move the arrow of the legend to better see the higher velocities
Mold erosion
Note 1: Using Mold Erosion, you can predict which areas will exhibit excessive mold
degradation due to high velocities.
Note 2: Using Mold Erosion, we can also detect how the liquid is directly colliding
the sand core because of the inlet design. To avoid this problem, it could be a good
idea to change the inlet attack.
83
Step 18
a) Click on the Solid Fraction result.
Note: Using Solid Fraction, you can determine if there will be any solid areas during
filling. A value of 0 corresponds to a completely liquid material, while a value of 1
corresponds to a completely solid material. Since there are no solidified areas during
the filling, we have a margin to decrease a little bit the inlet velocity avoiding the
direct collision with the sand core.
84
Step 19
a) Click on Add/Edit Gate to modify the inlet.

b) Click on Gate move tools to modify the angle of attack of the inlet.
c) Rotate the inlet around X-axis 20 degrees.
d) Click on the right mouse button to confirm.
Step 20
b) Select Filling and Solidification Analysis.
d) Click on the Run button to start the calculation.
85
Step 21
Step 22
a) Click on Solidification to open the Solidification result.
b) Click on Solid Fraction, the percentage must be in 0.7
c) Click on the Play button to start the animation.
Note: Liquid Fraction helps you understand the solidification behavior within the
part. In the animation, solidified material (above 0.7) is transparent, while liquid
material (below 0.7) is shown in color. Shrinkage porosity is more likely to occur in
isolated liquid regions.
86
Step 23
a) Click on Porosity to open the Solidification result.
b) Move the Porosity percentage to 20%
Note: This result means that blue regions have 20% of porosity (void). Increase the
percentage value to see real porosity size.
Step 24
a) Now, let’s create a real filling system.
b) First of all, we’ll need to delete the previous inlet. Click on Add/Edit
Gate and press the delete keyboard key.
c) Open the Geometry tools.
d) Inside Circles, select the button “circle by center and point”.
87
e) Click on the Surface showed in the right image to start designing the
Filling system.
f) Click on Create New Part.
Step 25
a) Create a circle of diameter 18mm.
b) Click on Push-button.
c) Select the created circle and pull until it reaches 70mm long.
d) Click on the Move button.
e) Select the cylinder we have created.
88
Step 26
a) Click on the center of the end of the cylinder and drag the cylinder
to the center of the surface where we had previously created the
ingate.
b) Select the arrow and move the cylinder along Y-axis -60mm.
89
Step 27
a) Click on the revolve face button.

b) Select the end surface of the cylinder to revolve.
c) Select the line showed at the right image as the rotation axis.
d) Rotate the Surface 90º.
Step 28
a) Click on the circle by center and select the extreme of the created
geometry.
b) Select the center of the circle.
c) Select the perimeter of the circle.
d) Click on Push-button.
e) Select the Surface Previously created.
f) Pull the Surface until it reaches 170mm.
90
Step 29
Once we have designed the filling system, let’s exit the geometry tools and go back
to casting tools.
a) Click on Casting.
b) Click on the designate filling system.
c) Select the geometry Previously designed.
d) Click on Designate Surfaces as Gates.
e) Select the top Surface of the Filling system to create the inlet.
91
Step 30
a) Click on Components.
b) Click on Riser's button.
c) Click on the region where we had problems with Porosity.
d) Change the risers Modulus to 0,8 cm to increase its size.
e) Repeat the same actions to create a second riser.
92
Step 31
a) Click on the Mold button.

b) A new message will pop up to resize the old mold size. Click on Yes.
c) The mold will be automatically resized.
Step 32
a) Click on Basic Setup.
b) Change the initial velocity to 0.5 m/s.
c) Click on the Run Analysis button.
d) Select both Filling and Solidification analysis and click Run.
93
Step 33 Analyzing Temperature with respect to filling
a) Let’s Analyze the results.
b) Click on Temperatures
c) Click Play to start the animation.
Note:
Switch off the Core component in Legend Manager to view the correct color map.
Step 34 Analyzing Solid Fraction

a) Click on Solid Fraction
b) Click Play to start the animation
94
It’s important to discard that we don’t have early solidification during filling to avoid
casting defects like misruns. In our case, it looks like filling in 6 seconds, is not
providing us this kind of problem and there are solidified areas during filling.
Step 35 Last Air

a) Click on Last Air
The last air is showing as most of the air inside the mold is being trapped inside the
risers. Despite air trapped is not a big issue in sand molds because its permeability,
risers will also help to prevent this kind of defects in our component.
Step 36 Solid Fraction
b) Click on Solid Fraction under solidification results.
c) Set the percentage to 0.7%
95
Note: We can see how risers are feeding material to the top region during the
solidification.
Step 37 Check Porosity
a) Click on Porosity.
b) Set the percentage to 100%
Riser filling will be

removed to neglect
the porosity
Risers, filling system

and core will be
removed, and the part
will be free of defects.
96
Analyzing porosity in percentage
20 % 60% 100%
• Porosity percentage shows areas where the ratio of voids to solid areas is
greater than or equal to the specified value. Click twice to change the
percentage value.
• To remove/reduce/relocate shrinkage defects in high pressure die casting:
• Reduce the area of the critical zone to obtain a faster cooling rate.
• Place runner gates close to the critical zone.
• Enlarge the gate and/or runners to feed the critical zone.
• Add ribs to the cast walls to improve feeding.
• Increase pressure on the metal.
• Place cooling channels to cool the critical zone.
Step 38 Analyze Velocities
• Velocities represent the filling process using vectors, allowing you to detect
turbulence and velocities. Click twice to change the visualization mode and
set maximum and minimum values.
97
• Besides using velocities during mold filling, you can use callout points to
analyze the filling behavior in different areas and to prevent turbulence due
to poor design.
Step 39 Cold Shuts
• Cold Shuts shows in colored areas where two fronts of material meet
and what the temperature difference is. This option is useful for
predicting cold unions. Set the maximum and minimum values to
check the differences.
• How to solve cold shuts:
• Adjust pouring metal.
• Modify the design.
• Modify the gating system.
98
Step 40 Filling Time
99
Step 41 Analyze Pressure
• Pressure displays changes in pressure during filling (Pascals).

• Inspire Cast solvers are biphasic; that is, the pressure of the air inside the
mold is computed in addition to that of the liquid.
• You cannot plot the air pressure in Inspire Cast, open the H3D file in
HyperView to visualize the air pressure.
Step 42 Analyze Niyama Criteria
• The Niyama criterion function is commonly used by foundries to

detect solidification shrinkage defects.
• Click once to display the total values; however, remember that each
material has a different range of critical values, so click again to select
the maximum value. In this case, for aluminum, select 0.3.
• Make sections along the geometry to analyze microporosity inside

the part.
100
• Remember that the lower the value, the higher the possibility of
microporosity. So, values close to 0 will show areas with higher
porosity.
Niyama value under 0.3 Original Niyama value
Since microporosity results from microporosity, the best way to prevent micro-
porosity is to eliminate solidification shrinkage.
Step 43 Analyze Mold Temperature
Mold Temperature shows temperature changes in the mold during the solidification
process.
101
6 Low-Pressure Die-Casting
(LPDC)
Low pressure die casting is a variant of the casting process also known as counter
gravity filling (low velocity of injection) where you have better control of the fluid
during filling. The ingate position should be at the bottom of the part, and the material
must fill from the bottom to the top.
• Low pressure die casting is a metal casting process generally used in

situations that require high-quality manufacturing.
• In low-pressure casting, molten aluminum is slowly drawn into a
metal mold or die through a riser tube while kept under constant and
controlled pressure.
• This process helps avoid oxidation, cold currents, and air inclusions,
generally producing the excellent surface finish and highly accurate
dimensions.
• It is much slower and therefore more costly than high pressure die
casting.
Low pressure die casting steps
102
Final component
Original design Inspire cast setup with best setup
103
Filling Requirements:
• Avoid turbulence during filling
• Homogeneous advancing front line
• Fill from the bottom to the top
6.1 Setting up of LPDC
• Select the Low-Pressure option to simulate the low

pressure die casting process.
• To set up low pressure die casting, enter values for the
machine pressure curve
• This is a low-pressure machine curve. In Inspire Cast, you

must consider the curve for the pressure inside the cavity.
• In this machine pressure curve, the absolute pressure

(prel+1 atm) is used, but in Inspire Cast you need to enter
the relative pressure (starting from 0).
104
• Then enter the distance between the free surface in the crucible and the mold
(ingate).
• Distance: enter the distance between the free surface in the

crucible and the mold (ingate).
Note: Enter the distance between the ingate and the free surface of the crucible.
Pressure curve values will be entered in the mbar.
105
6.3 Tutorial: Wheel Rim
Step 1
b) Click File/Open Exercise6-lowpressure.x_b
Step 2: Let’s select the Casting Part.

a) Click on Cast Part.
b) Select Geometry.
c) Set the casting material as Aluminum and select the AC-42100 alloy.
d) Click on the Material Property viewer to see the material properties.
Click on the right mouse button to exit the context and confirm the selection.
106
Step 3
a) Click on the Gravity button to move the part with respect to its
position in the mold.
b) This time the part is correctly aligned with the Gravity direction so
just click on the right mouse button to confirm the current direction.
Step 4
a) Click on the designate gate.

b) Click on the middle of the front of the Wheel
Note: Inlet (gate) is the area where the material enters the piece.
107
Step 5
a) Click on Low Pressure.
b) Set distance value to 600 mm and enter the pressure curve.
Pressure
Time (s)
(mbar)
0.0 140
3.0 160
5.0 180
7.0 200
108
Note: Define the Distance from the free surface (vertical distance between the liquid
free surface in the crucible and the mold ingate).
Step 6
a) Click on the Run Analysis button.

b) Select both Filling and Solidification analysis.
c) Set the element size to 5mm.
d) Click on Run.
e) They stalk, the sleeve, and the mold will be automatically created
after the click
Step 7
b) Click on Temperatures
c) Click Play to start the animation
109
Step 8
b) Click on Solid Fraction under filling results.
c) Click Play to start the animation
Note 1: 0 value represents liquid material, areas where there will be no filling issues
and 1 represents solidified areas during the filling.
Note 2: The solid fraction result shows like there are no solidified regions inside.
110
Step 9
b) Click on Velocity under filling results.
c) Click Play to start the animation.
Note. We can observe turbulences at the union between the wheel and the stalk due
to the high velocities (around 7 m/s) so based on velocities result and since there are
no problems of early solidification during the filling (as we have seen at the previous
slide) we could decide to decrease the pressures to fill slower the wheel and avoid the
turbulences.
111
Step 10
a) Click on Last Air
Note: The last air is showing as most of the air inside the mold is being trapped at
the top surface. This is not a big issue because there’s a partition line and the air will
scape but probably forming a flash defect in the region.
112
Step 11
b) Click on Cold Shuts under filling results.
Note. Cold shuts result is showing the temperature difference between the average
of two fronts and the initial temperature (inlet temperature).
Step 12
b) Click on Solid Fraction under solidification results.
113
• How do I analyze velocities in Inspire Cast?
• Velocities represent the filling process using vectors, allowing you to

detect turbulence and velocities. Click twice to change the
visualization mode and set maximum and minimum values.
• In tilt pouring, the velocity factor is not much important compared to

gravity or HPDC. Here, we can see velocity of flow is close to 0 m/s.
Step 13 Cold Shuts

Cold Shuts shows in colored areas where two fronts of material meet and what the
temperature difference is. This option is useful for predicting cold unions. Set the
maximum and minimum values to check the differences.
• Modify the gating system
114
Step 14 Filling Time
• Filling Time shows the time it takes the material to reach different
areas within the part, according to a color legend.
• Analyzing the filling time results, you can determine if you need to
modify the design of the right channel to avoid the isolated front of
liquid.
Step 15 Solid Fraction

Solid Fraction displays areas where solidification will occur. These multicolored areas
will not fill completely and are therefore prone to a shortage of material. Based on
the results, you may need to increase the pressure, increase the velocity, or reduce
the filling time to prevent shortage of material.
POROSITY
SURFACE EFECTS
115
A value of 0 represents liquid material, while 1 represents solid material.
Step 16 Pressure
• Inspire Cast solvers are biphasic; that is, the pressure of the air inside the
mold is computed in addition to that of the liquid. You cannot plot the air
pressure in Inspire Cast, open the H3D file in HyperView to visualize the air
pressure.
• Clamping force is the pressure the machine has to exert to keep the mold
closed during the filling/solidification of the die. Clamping force is used to
estimate the machine tonnage. It can be calculated as the metal pressure
times the projected area. 𝐹 = 𝑃𝑥𝐴
116
*Note: Negative Pressure will
appear when relative pressure is
under atmospherical pressure
Step 17 Niyama Criterion
The Niyama criterion function is commonly used by foundries to detect solidification

shrinkage defects. Click once to display the total values; however, remember that
each material has a different range of critical values, so click again to select the
maximum value. In this case, for aluminum, select 0.3. Make sections along the
geometry to analyze microporosity inside the part. Remember that the lower the
value, the higher the possibility of microporosity. So, values close to 0 will show areas
with higher porosity.
Niyama value under 0.3 Original Niyama Value
Note: Since microporosity results from microporosity, the best way to prevent
microporosity is to eliminate solidification shrinkage.
117
118
7 High-Pressure Die-Casting
(HPDC)
High-pressure die casting uses a machine to inject molten metal into permanent metal
dies under high pressure. It is a good technique for manufacturing complex parts with
a high degree of accuracy, particularly lightweight parts with thin walls that require
consistent dimensions. The high pressure is needed to fill the mold completely and
avoid solidification during the casting process. High-pressure die casting utilizes two
distinct velocities. The molten metal is first pushed at a low velocity (1st velocity) in
order to avoid turbulence and the formation of bubbles. Just before the material
enters the mold, the velocity increases (2nd velocity) and the molten metal is injected
very quickly into the die assembly to fill it completely.
• Filling behavior is very important in high-pressure die casting.
• A homogeneous front line is crucial to obtaining a cast component that is

free of defects.
• Moving air from one side to the other is the main concern if you want to
avoid front collisions, which will cause turbulence and air inclusions in the
part.
Filling requirements:
• Move air to a specific location

Use the Advanced Ingate option to design your virtual ingates and avoid designing
ingates in CAD and save time.
The ingate will be positioned perpendicular to the selected point, and it will be
projected over the curved surface after meshing.
119
• An overflow is commonly placed at a location of trapped air.
• Overflows are cavities in the die, which act as vents for air to escape and
traps for excess metal flow.
• Using the simulation results, you can predict where to place the overflows to
prevent porosity.
Overflows
• Once you position the ingates, you need to design the filling system
(runner).
• Inspire Cast is an excellent tool for analyzing the runner to prevent
turbulence, which creates air bubbles that travel through the mold.
• In Inspire Cast, you can optimize the runner design.
• Using the Velocity Vectors option, you can analyze filling patterns,
velocities, and the time it takes the liquid to reach the part.
• Use these simulation results to redesign the runner.
•
Filling requirements:
• Fluid must reach the ingates at the same time.
• Avoid turbulence when filling the runner.
• Avoid low/high velocities at the ingate.
120
When setting up high-pressure die casting in Inspire Cast, three scenarios are
possible:
1. Part + runner
2. Part only
3. Part + half of the runner
7.1 Setting up of HPDC
Original Inspire Design Final Design without defects
Process Parameters Options
• By point
• Initial Velocity: enter values in meters per second. Typical values for
Initial Velocity are 0.2 – 0.5 m/s.
• Second Phase Velocity: enter values in meters per second. Typical
values for Second Phase Velocity are 2.0 – 5.0 m/s.
• Phase Change Point: click Select to designate. Click any point on the filling
system to specify where the initial velocity changes to the second phase
velocity.
Note: Make sure to set the phase point for the second velocity before the material
arrives at the casting part.
• By time: define the piston velocity profile. You can enter values in the table
or edit the points on the graph. Use the buttons below the
table to add a new row after a selected data point, add a new row after the
121
last data point, or delete a selected row. Time is in seconds and velocity in
meters per second.
122
7.2 Tutorial: Wash Basin
Step 1
c) Click on Open Model Exercise7HPDC.x_b
Step 2
a) Select Length units (mm) from the right bottom corner.
b) Click on Cast Part to designate the casting part.
c) Define Cast Material (Aluminum AC-42100) and Temperature
(718°C)
123
Step 3: The next step is to define the gravity direction for the casting.
a) Define Casting Gravity.
b) Modify direction according to user requirements.
Step 4
a) Click the Add/Edit Gate icon to provide ingate.
b) Select pre-existing ingate or select surface to generate one.
c) Set the size and shape of ingate
124
Step 5
a) The Mold icon in the Component process setup to generate mold.
b) Define Mold Material and Temperature as shown in the picture
Note: User can also add or designate other components as shown
Step 6
a) Under the Casting setup icon selects Basic Setup.
b) Select Initial velocity or Filling time.
125
Step 7
For Analysis, User can select Filling/ Solidification or Both at the same time.
a) Here, Element Size needs to be defined before going for analysis.
This function creates meshing for geometry.
b) Click Run.
c) Once the simulation calculation Will is finished, Green flag Will
appear on analyzing icon.
d) Users can also select results by clicking the view button.
126
Step 8
a) Using analysis explorer, user can Access different type of results for
both filling and solidification stage.
b) By Clicking the Play button, we can start the animation of the
process.
*Note: User can modify the value of min and max temperature within range to see
different values at various points.
127
Step 9
a) Let’s change the minimum temperature to 680 and 700o C in our
design and observe the flow behavior.
b) Click the Play button to start the animation.
Note: We can observe that due to design or gating system flow front is different at
various places. In some area’s fluid cools down earlier than other spots. This can end
up causing some casting defects. Our next objective is to redesign the part and
gating system to avoid this kind of situation.
128
Step 10
a) In the previous design, star-shaped fines on the top of the model were
designed such a way that during the filling process it was causing
turbulence inflow front.
In the latest design, this shape was oriented with some angle which can possibly avoid
problems associated with previous flow simulation. As well as gate was also
redesigned
Note: Design of part and gating before. Note: Design of part and gating
after.
Step 11
a) Performing the same steps to analyze the modified model.
b) Simulation results are shown below:
c) The next step is to check the air entrapped and porosity.
d) From the result, we can observe the defects of last air trapped
inside the final product.
e) To overcome this problem, a more advanced gating system and
overflow vents were introduced.
129
Note: We can observe that in our modified design flow front and temperature
distribution is significantly steady.
Step 12 Run analysis and prevent typical casting defects for the high pressure die
casting process
b) Click on Cast part to designate the casting part.
c) Define cast material (Aluminum AC-42100) and temperature

(718°C).
130
Step 13: The next step is to define the gravity direction for the casting.
a) Define casting gravity.
b) Modify direction according to user requirements.
Step 14
a) The select filling system as shown in the picture.
b) Click and designate the surface as a gate.
131
Step 15
a) Define mold material and temperature as shown in the picture.

b) Define overflows as additional components.
c) Click the Mold icon in the Component process setup to generate
mold.
132
Step 16
a) Under Casting setup icon select High-Pressure Die casting
b) Select High-Pressure Die Casting Parameters.
Step 17
a) For Analysis, User can select Filling/ Solidification or Both at the
same time.
b) Here, Element size needs to be defined before going for analysis.
This function creates meshing for geometry.
c) Click Run.
d) Once the simulation calculation Will is finished, Green flag Will
appear on analyzing icon.
133
Step 18
both filling and solidification stage.
process.
Note: User can modify the value of min and max temperature within range to see
134
Step 19
a) Let’s check for one casting defect and Click Last Air.
Note 1: The Last Air option shows you where the air will become trapped against the
walls during the filling process in an instant view. To solve this issue, increase the
ingate's angle of attack.
Note 2: As we can see with compare to previous design, air trapped inside casting is
almost negligible while there is some air in the vent system and filling system.
Note 3: User can obtain the desired result and can also analyze different result types
to overcome the defects as necessary.
135
Step 20 Analyze Velocities

• Besides using velocities during mold filling, you can use callout points to
analyze the filling behavior in different areas and to prevent
turbulence due to poor design.
Step 21 Analyze Cold Shuts
• Cold Shuts shows in colored areas where two fronts of material meet
and what the temperature difference is. This option is useful for
predicting cold unions. Set the maximum and minimum values to
check the differences.
136
Step 22 Analyze Filling Time
• Filling Time shows the time it takes the material to reach different areas
within the part, according to a color legend.
• Analyzing the filling time results, you can determine if you need to modify
the design of the right channel to avoid the isolated front of liquid.
137
Step 23 Analyze Solid Fraction
Step 24 Analyzing Pressure

• Pressure displays changes in pressure during filling (mbar).
• Inspire Cast solvers are biphasic; that is, the pressure of the air inside the mold
is computed in addition to that of the liquid. You cannot plot the air pressure
in Inspire Cast, open the H3D file in HyperView to visualize the air pressure.
times the projected area.
F=PxA
138
-0.1
Note: Negative pressure will appear when relative pressure is under atmospherical
Pressure
• Temperature shows changes in temperature during the solidification
process. Set the maximum and minimum temperatures to check the
differences at various points.
• If the filling was calculated previously, solidification temperatures will start
with the last temperatures of the filling. If not, it will start at a constant
temperature.
139
Step 25 Analyze Liquid Fraction
• Liquid Fraction displays the last areas to solidify (liquid material) in red so you
can predict shrinkage porosity.
• Click twice to change the solid fraction value, which is set to 0.7 by default (in
most cases, this corresponds to the value at which the liquid stops flowing).
In the animation, solidified material (above 0.7) is transparent, while liquid
material (below 0.7) is shown in red. Shrinkage porosity is more likely to occur
in isolated red areas.
• Liquid Fraction is useful for analyzing the behavior of the liquid during
solidification. Unlike in gravity casting, overflows and runners won’t feed the
part during solidification because of the thin ingate sections.
• Liquid Fraction and Mold Temperature results will provide you with valuable
information to help you design cooling channels.
Step 26 Analyze Porosity Percentage
• Porosity % shows areas where the ratio of voids to solid areas is greater than
or equal to the specified value. Click twice to change the percentage value.
• To remove/reduce/relocate shrinkage defects in high pressure die

casting:
• Reduce the area of the critical zone to obtain a faster cooling rate.
140
• Place runner gates close to the critical zone.
• Enlarge the gate and/or runners to feed the critical zone.
• Add ribs to the cast walls to improve feeding.
• Increase pressure on the metal.
• Place cooling channels to cool the critical zone.
20% Porosity 60% Porosity 100% Porosity
Step 27 Analyzing Niyama Criteria
Original Niyama Niyama value under 0.3
141
*Since microporosity results from microporosity, the best way to prevent
microporosity is to eliminate solidification shrinkage
• The Niyama criterion function is commonly used by foundries to detect

solidification shrinkage defects.
• Click once to display the total values; however, remember that each
material has a different range of critical values, so click again to select the
maximum value. In this case, for aluminum, select 0.3.
• Make sections along the geometry to analyze microporosity inside the part.
• Remember that the lower the value, the higher the possibility of
microporosity. So, values close to 0 will show areas with higher porosity.
Step 28 Analyze Mold Temperature
• Mold Temperature shows temperature changes in the mold during the

solidification process.
• Mold temperature, liquid fraction, and porosity can be used to determine
where to place cooling channels to cool down a particular region.
142
8 Investment Casting
8.1 Introduction to Investment Casting
The “investment” in investment casting refers to the process of coating the wax
pattern in a ceramic slurry. “Investing” is any process in which an object is dipped into
liquid, and a layer of the liquid attaches itself to the object.
• Investment casting is an industrial process based on Lost wax- casting, Today,

more advanced waxes, refractory materials, and specialist alloys are typically
used for making patterns. Investment casting is valued for its ability to produce
components with accuracy, repeatability, versatility, and integrity in a variety of
metals and high-performance alloys.
• Much of the wax used in investment casting can be reclaimed and reused.
Investment casting derives its name from the pattern being surrounded by a
refractory material. The material is poured into a cavity in a refractory material
that is an exact duplicate of the desired part. Due to the hardness of refractory
materials used, investment casting can produce products with exceptional
surface qualities, which can reduce the need for secondary machine processes.
• The process can be used for both small castings of a few ounces and large
castings weighing several hundred pounds. Investment casting can produce
complicated shapes that would be difficult or impossible with other casting
methods. It can also produce products with exceptional surface qualities and low
tolerances with minimal surface finishing or machining required.
To choose the ingate position in investment casting, use the same criteria as for
gravity casting.
Filling Requirements:
143
• Needs the proper gating system
144
8.2 Tutorial: Brake Caliper
Step 1
b) Click on New Model
c) Click on Open Model Exercise8-investment.x_b
145
Step 2
c) Select Cast Material (Aluminum A356) and Temperature (718°C) in

the dropdown box.
146
Step 3: The next step to define gravity direction for the casting.
a) Click on the Gravity icon and Define Casting Gravity.
b) User can modify direction by using geometry box
Step 4
a) Click to designate the Filling system.

b) Click the add/edit Gate icon to provide ingate.
c) Select pre-existing ingate or select surface to generate one or Set size and
shape of ingate.
147
Step 5
a) Under Casting, setup icon selects Gravity setup casting.

b) Select Filling time. Provide Investment Casting setup parameters.
148
Note: We do not require mold as we use shell made of sand coating for the investment
process.
Step 6
a) For Analysis, User can select Filling/ Solidification or Both at the same time.
b) Here, Element size needs to be defined before going for analysis. This
function creates meshing for geometry.
c) Click Run.
d) Once the simulation calculation Will is finished, Green flag Will appear on
analyzing icon.
e) Users can also select Result by clicking the view button.
149
Step 7
a) Using analysis explorer, user can Access different type of results for both the
Filling and Solidification stage.
b) By Clicking the Play button, we can start the animation of the process.
Note: User can modify the value of min and max temperature within range to see
Step 8
150
c) Click Porosity to observe the defects position and cause in our design.
d) Click the Play button to start the animation.
• The most common investment casting processes are lost wax and lost
foam.
• In Inspire Cast, you can simulate the lost wax process once the wax has
been removed from the mold (pouring the liquid in the shell cavity).
Since the mold is destroyed during the process, parts with complex geometries and
intricate details can be created in investment casting.
Investment Casting without Investment casting using inspire

inspire cast cast
Step 9 Analyzing Velocity

Velocities represent the filling process using vectors, allowing you to detect
turbulence and velocities. Click twice to change the visualization mode and set
maximum and minimum values.
151
Filling Time shows the time it takes the material to reach different areas within the
part, according to a color legend.
Analyzing the filling time results, you can determine if you need to modify the design
of the component to avoid the isolated front of liquid.
152
Step 11 Analyzing Solid Fraction
A value of 0 represents liquid material, while 1 represents solid material
Step 12 Analyze Pressure
Pressure displays changes in pressure during filling (Pascals).
• Inspire Cast solvers are biphasic; that is, the pressure of the air inside
the mold is computed in addition to that of the liquid. You cannot
plot the air pressure in Inspire Cast, open the H3D file in HyperView
to visualize the air pressure.
153
-25.55 mbar
Negative Pressure will appear when relative Pressure is under atmospherical

Pressure
Step 13 Analyze Niyama Criterion

The Niyama criterion function is commonly used by foundries to detect solidification
shrinkage defects. Click once to display the total values; however, remember that
each material has a different range of critical values, so click again to select the
maximum value. In this case, for aluminum, select 0.3. Make sections along the
geometry to analyze microporosity inside the part. Remember that the lower the
value, the higher the possibility of microporosity. So, values close to 0 will show areas
with higher porosity.
154
Since microporosity results from microporosity, the best way to prevent
microporosity is to eliminate solidification shrinkage.
155
9 Gravity Tilt Pouring
9.1 Introducing to Tilt Pouring
Gravity tilt pouring is another permanent mold process where the mold starts
horizontal and is gradually tilted into a vertical position during the filling process, so it
is filled in a controlled manner, with low turbulence and a moderate flow rate.
This technique compensates for the effect of free fall at the beginning of the pouring
process and helps to avoid air inclusions.
Initial Position
Final Position
• Gravity tilt pouring is a variant of the gravity process where you have better
control of the fluid during filling.
• In gravity tilt pouring, a holding cup is commonly used, where the metal is
poured while the mold is horizontal. To select the ingate, just select the
surfaces where the liquid enters the mold.
Red indicates the ingate location Holding cup
156
To simulate gravity tilt pouring, you need to enter a Rotation time, which is equal to
the Filling time. The final position is the actual position of the casting (0º). The Initial
position will vary between 90º to 0º.
• To define the rotation, first select the global axis by clicking X, Y, or Z.

• Click the Rotation Point button and pick a point on the geometry.
Note: Rotation will follow the XYZ coordinate axis order; if you select Y as the axis of
rotation, then the rotation will turn Z over X; if you select Z, then X will rotate over Y.
• Gravity Tilt filling known as tilt casting is an exceptional filling technique

where the crucible is attached to the gating system and both are slowly
rotated so that the metal enters the mold cavity with little turbulence.
• The goal is to reduce porosity and inclusions by limiting turbulence. For most
uses tilt filling is not feasible because the following inherent problem: if the
157
system is rotated slow enough to not induce turbulence, the front of the
metal stream begins to solidify, which results in misruns.
• If the system is rotated faster it induces turbulence, which defeats the
purpose.
Pouring
Primary position Finished Pour
Original
Design
Inspire Cast Setup Final Component
with Best Setup!
158
9.2 Tutorial: Gear Housing
Step 1
c) Click on Open Model Exercise9-TiltPour.x_b
Step 2
Select Cast Material (Aluminum A356) and Temperature (718°C) in the dropdown
box.
Length units
(mm)
Step 3: The next step is to define gravity direction for the casting.
a) Click on the Gravity icon and Define Casting Gravity.
b) User can modify direction by using geometry box
c) According to user requirements.
159
Step 4
a) Click the Add/Edit Gate icon to provide ingate.
b) Select pre-existing ingate or select surface to generate one
Or Set the size and shape of ingate.
Step 5
a) Click on the drop-down box for various material types and define mold
material and temperature as shown in the picture.
b) Click the Mold icon in the Component process setup to generate mold.
Note: User can also add or designate other components as shown
160
Step 6
a) Under Casting, setup icon selects Gravity setup casting.
b) Select Filling time. Select tilt pouring and specify rotation axis,
rotation point, and angle with respect to rotation time.
Filling Time (s) - Select this option if you have calculated the exact filling time required
for your process. Units must be in seconds. The flow rate will be calculated
automatically based on the defined ingate.
𝑣
𝐹𝑡 =
𝐴𝑖𝑛𝑔𝑎𝑡𝑒 ∗ 𝜈
Spoon Height - Use this option when you have totally manual ladle operators. The
flow rate depends on the area defined as the ingate. You can also choose the ladle
pouring height (mm) with respect to the mold. Spoon height is the distance between
the ladle and the mold when the liquid is being poured. If you don’t know this value,
use a value around 10–30 mm. Inspire cast internally calculates the velocity based on
the spoon height.
𝑣2
𝐻=
2𝑔
Flow Rate - The flow rate is the poured metal volume in kg divided by the filling time
in seconds. This parameter can be calculated when using an auto pour ladle, bottom
pours ladle, or stop and rod ladle, etc.
𝑄 = 𝐴𝑖𝑛𝑔𝑎𝑡𝑒
̈ 𝑣⋅𝑃
161
Time vs angle curve
• Rotation axis: in this simulation our rotation axis is X.
• Rotation Point: rotation Point is shown in the figure.
• Rotation Table: enter a time vs angle curve. To set a positive or negative

angle, check the sense of rotation from the final position to the original
position following the right-hand rule to determine the sign.
Rotation Point
0°
+90°
162
Step 7
a) For Analysis, User can select Filling/ Solidification or Both at the same
time.
b) Here, Element size needs to be defined before going for analysis. This
function creates meshing for geometry.
c) Click Run.
d) Once the simulation calculation Will is finished, Green flag Will appear on
analyzing icon.
e) Users can also select results by clicking the view button.
Step 8
both filling and Solidification stage.

process.
* Note: User can modify the value of min and max temperature within range to see
Step 9 Analyze Porosity
a) Click Porosity to observe the position of this defects and cause in our design.
163
20 % Porosity
60 % Porosity
90 % Porosity
Step 10 Analyze Velocity

• In tilt pouring, the velocity factor is not much important compared
to gravity or HPDC. Here, we can see velocity of flow is close to 0
m/s.
164
Step 11 Analyze Cold Shuts
• Cold Shuts shows in colored areas where two fronts of material meet and
what the temperature difference is. This option is useful for predicting cold
unions. Set the maximum and minimum values to check the differences.
• Filling Time shows the time it takes the material to reach different areas
within the part, according to a color legend.
• Analyzing the filling time results, you can determine if you need to modify
the design of the component to avoid the isolated front of liquid.
The minimum value is set to 0.02 second to better analyze the filling difference of
the part.
165
Step 13 Analyze Solid Fraction
High velocity Porosity
Surface Defects
Low velocity
• Solid Fraction displays areas where solidification will occur. These

multicolored areas will not fill completely and are therefore prone to
a shortage of material. Based on the results, you may need to increase
the pressure, increase the velocity, or reduce the filling time to
prevent shortage of material.
A value of 0 represents liquid material, while 1 represents solid material.
Step 14 Analyzing Pressure

• Inspire Cast solvers are biphasic; that is, the pressure of the air inside
the mold is computed in addition to that of the liquid. You cannot plot
the air pressure in Inspire Cast, open the H3D file in HyperView to
visualize the air pressure.
166
times the projected area.
Negative Pressure will appear when relative pressure is under atmospherical

pressure
Step 15 Analyze Temperature during Solidification
167
Temperature shows changes in temperature during the solidification process. Set
the maximum and minimum temperatures to check the differences at various
points.
• If the filling was calculated previously, solidification temperatures will start

with the last temperatures of the filling. If not, it will start at a constant
temperature.
Step 16 Analyze Niyama Criteria

• The Niyama criterion function is commonly used by foundries to detect
solidification shrinkage defects. Click once to display the total values;
however, remember that each material has a different range of critical
values, so click again to select the maximum value.
• In this case, for aluminum, select 0.3. Make sections along the geometry to
analyze microporosity inside the part. Remember that the lower the value,
the higher the possibility of microporosity.
• So, values close to 0 will show areas with higher porosity.
Original Niyama value
Niyama value under 0.3
168
Step 17 Analyzing Mold Temperature
Mold Temperature shows temperature changes in the mold during the solidification
process.
Mold Temperature shows temperature changes in the mold during the filling process.
169
Appendix A
Learn Casting and Solidification with Altair Inspire Cast
Powerful and Accurate Casting Simulation without the Complexity
Import Geometry Define Ingate Define Parameter Run Analyze Cast Final Part
By Sourav Das
170
A 1. Set-Up
Steps
Setup Toolbar
With the Setup Toolbar, you can create different Cast Part, Gate, and Components.
Cast Part - Designate Casting Part
• Designate Casting Part

• Select the casting parts and define the material, alloy, and temperature.
• Use the micro dialog options to define the material, alloy, and
temperature.
171
• Micro Dialog Options:
• Material Viewer to examine the material's Thermal, Phase-Change,
and Fluid properties.
• Material Select from common ferrous and non-ferrous
materials.
• Alloy Select from common alloys of the chosen material
• Temperature Enter the temperature of the material.
• Material Viewer:
Select a material and an alloy for the casting parts and examine its
Thermal, Phase-Change, and Fluid properties.
• Thermal Property:
• Density: the mass divided by the volume (kg/m3).
• Specific Heat: the heat energy required to increase the
temperature of a unit quantity (J/kg·K).
• Conductivity: the material's ability to conduct heat (W/m·K).
• Environment HTC: The Heat Transfer Coefficient with the
environment (W/m2·K).
• Phase-Change:
• Latent Heat: the amount of energy in the form of heat release
(J/kg).
• Liquidus Temp: the temperature above which the material is
completely liquid (ºC).
• Solidus Temp: the temperature below which the material is
completely solid (ºC).
• Solid Fraction: the graph shows the thermal evolution of the alloy
during solidification.
• Fluid:
• Dynamic Viscosity: the graph represents the resistance of the
fluid to deformation (Pa ·s)
172
Designate the Filling System
• Select the runners through which the molten metal flows to enter the mold
cavity.
Cast Part - Set Gravity Direction

Orient the model with respect to the direction of gravity (the z-axis) in order
to control the flow of the liquid as it enters the mold and solidifies.
• Micro dialog Options
Rotate the model, align the normal of a surface to the direction of gravity, or
flip the model vertically.
• Rotate: Rotate the model.
• Align: select a surface to align its normal to the direction of
gravity (negative z-axis).
• Flip: Flip the model vertically along the direction of gravity
(negative z-axis).
173
Gate
• Identify predesigned gates or create and edit virtual gates.

• A gate, or ingate, is an inlet where the molten metal enters the mold. A
well-designed gating system is crucial for delivering smoothly flowing
material and minimizing turbulence.
Designate Surfaces as Gates
Identify any gates you've already designed in a CAD tool.
• Add/Edit Gate
• If you haven't designed any gates in a CAD tool, you can create and edit
virtual gates in Inspire Cast.
• Use the micro dialog options to define the shape, size, and position of the
gate:
• For a Rectangular gate, define the Height and Width.
• For a Circular gate, define the Radius.
• Click to use the Move tool.
174
• Micro Dialog Options
• Define the shape and size of the gate.
• Move: to move or change the angle of the gate
• Shape: Select circular or rectangular
• Size: Enter radius for a circular gate or Width and Height for a
rectangular gate
Component Cores
• A core is used to create the interior shape of a model. It is commonly

used in sand casting, but it can also be used in other processes.
• The core is placed into the mold cavity so that when the material is
poured, it displaces the pouring metal. After solidification, the core is
removed, revealing the void.
• Core - Designate Components

• Identify any cores you've already designed in a CAD tool.
• Add/Edit Core
175
• If you haven't designed any cores in a CAD tool, you can
create and edit virtual cores to Inspire Cast.
• Micro dialog Options
• Material Viewer: to examine the material's Thermal
and HTC properties.
• Material: Select the type of sand.
• Temperature: Enter the temperature of the
material.
Core creation Select material and temperature Core created
176
A 2. Geometry Modifications
Geometry Setup
• Designs with complex geometry, tight dimensional tolerances, and thin
sections tend to require more costly processes.
• Designs with tight tolerances and minimal draft may require special
molding processes.
Modify
Create
Runners, Risers, Overflows, Coolers
177
Geometry information:
• Inspire Cast supports several format files (Parasolid, Step, Catia, Solidworks,
ProE, etc.)
• You will find inside the geometry menu several tools to work with in case
you need to create or modify your geometry.
• If the model contains runners, risers, overflows, coolers, they can be
imported or created in Inspire Cast.
(a.) File Format
178
(b) Geometry Creation /Modification
With the Create Toolbar, one can create points, lines, rectangles, circles, and arcs in
different ways. We can patch holes and generate PolyNURBS entities.
Dropdown Contents
Points/Lines Rectangles Circles
• Create Point. • Create Rectangle by • Create Circle by 2

• Create Line. Corners. Diametric Points.
• Create • Create Rectangle by • Create Circle by
Polyline. Center and Corner. Center and Point.
• Create Rectangle by 3 • Create Circle by 3
Points. Points.
179
Arcs
• Create Arc Tangent to End.
• Create Arc by Center and Ends.
• Create Arc by 3 Points.
Trim/Break
• Cut part of the sketch (Trim).
• Divide your sketch in more simple elements (Break).
Trim
Break
(c) Point line ( Create and Edit)
Sketch a Point or Line - Sketch, edit, and extrude a point, line, or polyline.
• Geometry ribbon > Create group > Points/Lines tools
• Designate the sketch plane and enter sketch mode:
1. If there is already geometry, click a face.
180
2. If there is no geometry, you don't need to do anything. The global x-
y plane is designated as the sketch plane and you automatically
enter sketch mode.
• Optional: Click Create New Part to place the point, line, or polyline into a
new part.
• Right-click to exit sketch mode and enter sketch editing mode.
Alternative Shortcut Keys

Action Button
Constrain line to one direction
Enter sketch mode Double click

Enter sketch editing mode
Exit tool
or ESC
• Point
• Click
• Use snap points to create a point at a predefined point on your
models such as an end, middle, center, or intersection point.
• Line
181
• Click twice. You can resize the line by entering a length.
• Use snap points to draw a line that is perpendicular or tangent to
another line, and snap to predefined points on your model such as
end, middle, center, and intersection points.
• Polyline
• Click to create each point of the polyline. Right-click or double-click

to end the polyline. You can resize a line segment by entering a
length.
• Use snap points to draw polyline segments that are perpendicular or
tangent to other lines, and snap to predefined points on your model
such as end, middle, center, and intersection points.
• First, you need to be in sketch editing mode:
• If a sketch tool is active, right-click.
• If a sketch tool isn't active, double-click a face or sketch
curve.
• Choose from the following options:
• Reposition the point or line → Drag the point or line
• Resize the line → Click the line, and then enter a length.
Drag an endpoint
• Apply a sketch constraint to the line→ Right-click the line,
and then select a sketch constraint on the context menu.
• Right-click to exit sketch editing mode and enter push/pull mode.
182
Note:
• If you sketched the curve on a face, the curve is imprinted onto the face
and can no longer be edited when you exit sketch editing mode.
• If you sketched a curve that doesn't touch a face, faces are created from
any closed loops in the sketch. You can still edit the curve by double-
clicking a face.
(d) Rectangle Create /Edit
Sketch a Rectangle - Sketch a rectangle by defining two opposite corners, three

points, or the center and a corner.
• Geometry ribbon > Create group > Rectangle tools
enter sketch mode.
new part.
How to Create Rectangle

• Rectangle by Corners
1. Click to define one corner, and then click again to define the
opposite corner. You can resize the rectangle by entering a length
and a width.
183
2. Use snap points to draw a rectangle that is perpendicular or tangent
to other lines, and snap to predefined points on your model such as
• Rectangle by 3 Pts
1. Click twice to define one side, and then click a third time to define
the opposite side. You can resize the rectangle by entering a length
and a width.
• Rectangle by Center and Corner
1. Click to define the center, and then click again define a corner. You
can resize the rectangle by entering a length and a width.
• Rectangle - Edit
1. First, you need to be in sketch editing mode:
184
curve.
2. Choose from the following options:
• Reposition the rectangle→ Box select the rectangle and
drag it.
• Reposition a side → Drag the side
• Resize the rectangle → Click aside and enter a value.
• Apply a sketch constraint to the rectangle → Right-click the
rectangle, and then select a sketch constraint on the context
menu.
3. Right-click to exit sketch editing mode and enter push/pull mode.
* Note:
If you sketched the curve on a face, the curve is imprinted onto the face and
can no longer be edited when you exit sketch editing mode.
If you sketched a curve that doesn't touch a face, faces are created from any
closed loops in the sketch. You can still edit the curve by double-clicking.
Circle – Create /Edit

Sketch a Circle - Sketch a circle by defining three points, two diametric points, or the
center and a point.
• Geometry ribbon > Create group > Circle tools
enter sketch mode.
new part.
185
Circle -Create
Circle by 2 Diametric Pts
• Click twice to define the diameter. You can resize the circle by entering a
diameter.
• Use snap points to draw a circle that snaps to predefined points on
your model such as end, middle, center, and intersection points.
Circle by 3 Pts
• Click three times. You can resize the circle by entering a diameter.
Circle by Center and Corner
• Click to define the center, then click again define the radius. You can
resize the circle by entering a diameter.
186
Circle -Edit
1. First, you need to be in sketch editing mode:

curve.
2. Choose from the following options:
• Reposition the circle→ Drag the center point
• Resize the rectangle → Click the circle, and then enter a
diameter
• Apply a sketch constraint to the circle → Right-click the
circle, and then select a sketch constraint on the context
menu.
3. Right-click to exit sketch editing mode and enter push/pull mode.
Note:
clicking a face.
187
Arc- Create/Edit
Sketch an Arc - Sketch an arc by defining three points, tangency points and an
endpoint, or the center and endpoints.
• Geometry ribbon > Create group > Arc tools
enter sketch mode.
new part.
Keyboard shortcuts:
Action Button
Place points Click
Edit Rectangle\ Circles \ Arc Click while in sketch editing mode
Enter sketch mode Double-click geometry
Exit tool or Esc
188
Arc – Create
1. Arc Tangent to End
• Click near an endpoint of a curve, and then click again to define the arc. You
can resize the arc by entering a radius or an angle.
• Use snap points to draw an arc that is perpendicular or tangent to
other lines, and snap to predefined points on your model such as
2. Arc by 3 Pts
• Click to define the center of the arc length, and then click a second
and third time define the endpoints. You can resize the arc by
entering a radius or an angle.
• Use snap points to draw an arc that is perpendicular or tangent to
other lines, and snap to predefined points on your model such as
3. Arc by Center and Corner
• Click to define the center of the circle that the arc is a part of, and
then click a second and third time to define the endpoints. You can
resize the arc by entering a radius or an angle. Use snap points to
draw an arc that is perpendicular or tangent to other lines, and snap
189
to predefined points on your model such as end, middle, center, and
intersection points.
Arc - Edit
• First, you need to be in sketch editing mode:

curve.
• Choose from the following options:
• Reposition the arc → Drag the center point
• Resize the arc → Click the arc, and then enter a diameter
• Apply a sketch constraint to the arc → Right-click the arc,
and then select a sketch constraint on the context menu.
• Right-click to exit sketch editing mode and enter push/pull mode.
Note:
clicking a face.
190
Trim / Break
• Trim - Remove a segment of a sketch curve.

1. On the Geometry ribbon, in the Create group, in
the Trim/Break tool group, click the Trim tool.
2. Do one of the following:
To trim a segment, click it
• To trim multiple segments simultaneously, use box selection.
Break - Break a segment of a sketch curve.

1. On the Geometry ribbon, in the Create group, in the Trim/Break tool group,
click the Break tool.
2. Click a segment: Endpoints are placed at the breaks.
3. Optional: To detach the segment from the sketched curve, drag it.
191
Action Button
Select or remove the segment Click
Detach and move a cut segment

+ + drag
Copy a cut segment + drag
Enter sketch mode Double-click geometry
Enter sketch editing mode Esc
Sketch Location
The sketch can be done in any XYZ plane, or in the planar faces of solid geometry
already done.
While sketching, 6 additional buttons are available:
• Create New Part:
allows you to create a new part before you start sketching. Any sketching
curves will be imprinted onto the current part before the new one is created.
• Transfer Sketch:
allows you to move your current sketch to a new part.
• Convert Reference Lines to Sketch:
allows you to create sketch curves from reference geometry.
192
• Create a New Sketch Plane:
allows you to create a new sketch plane by selecting a new face.
• Move Plane:
allows you to move the sketch plane by opening the Move tool.
• Sketching Options:
allows you to modify your grid and snap settings.
Sketch Constraints
In sketch mode, right-click a curve or the connecting point between curves, and then
select a constraint on the context menu.
• Fixed → Constrain a sketch point, line, or curve so that it maintains a fixed
position relative to adjacent sketch curves. (The object itself is not fixed in
3D space. You can still move it by dragging.)Points, lines, circles, and arcs
can all be fixed. The edges of rectangles are separate entities and can be
fixed independently.
• Horizontal → Position line segments horizontally with respect to the
sketch plane.
• Vertical → Position line segments vertically with respect to the sketch
plane.
• Collinear → Align two or more-line segments.
• Parallel → Position two-line segments so they are parallel.
• Perpendicular → Position two-line segments so they are perpendicular.
• Targent → Position a line segment so that it is tangent to an arc.
• Concentric → Align two or more circles so they are concentric.
193
Patch Tool
• Used to fill in missing surfaces in order to create a solid. Also allows to remove
and remake bad or problematic surfaces
Note: To change the continuity of the patch where it meets an adjacent surface,
click on the edge. The continuity will toggle between linear and tangent.
Patch
PolyNURBS
PolyNURBS - PolyNURBS allows you to quickly create free-form solid geometry that
is smooth and continuous.
194
• A PolyNURBS object represents geometry as a NURBS surface surrounded by
a transparent, quad-only, polymesh cage. The shape of the PolyNURBS
object is the result of the modifications made to the cage, which can be
manipulated using the cage's faces, edges, and vertices.
• You can create PolyNURBS parts using the PolyNURBS tool and sub tools on
the Geometry ribbon.
• Create
• Wrap
• Fit
• Add\Remove blocks to the cage
• Split
• Bridge
• Sharpen
Modify Toolbar
With the Modify Toolbar you can push/pull faces, reflect and scale parts, do
Boolean operations, cut solids, simplify parts, extract mid surface, create fillets and
chamfer edges.
Push /Pull
This utility can be used to modify faces, curves or radius.

Click and drag a selected face/curve/radius in the direction of the desired location.
Manually input the displacement values is allowed too.
Reference point or base of the push/pull operation can be dragged or modified with
respect to another feature.
195
Revolve a planar face around an edge/line/cylindrical hole is also allowed.
Revolve Face
This utility can be used to revolve faces, curves or radii. Click and drag a select
d face/curve/radius in the direction of the desired location.
To designate the rotation axis, click an edge, line, or cylindrical hole. Selecting an
edge on another part projects the axis of revolution to the planar face that will be
rotated.
Choose from the following options:
• Drag the face, line, or 2D edge.
• Drag the white arrow on the compass.
• Enter an angle in the micro dialogue.
196
Action Button
Activate the Push/Pull tool P or double click
Make the object a new part

or
Exit tool Esc
Note
• To create a new part, hold down Shift or Ctrl while dragging.
• To reposition the axis of revolution using the Move tool, click in the micro
dialogue.
• Drag the rotation arrow by its midpoint to snap points. Clicking elsewhere
on the rotation arrow will temporarily disable snapping.
• Selecting a face from a 2D sheet automatically revolves the face a full 360
degrees. Once you drag the face, the only way to get back to a full 360
degrees is to change the angle.
197
Move Faces
The Move Faces tool works the same way as the Move Tool but is used to translate
and rotate holes, pockets, and surface features. You can also use it to copy features
by holding down the CTRL key while dragging to copy features. Features can be
extended by selecting the surface(s) and dragging them. It does not work on edges.
The tool uses a graphic manipulator to drag features to

a new location or rotate the feature.
Manipulators can be selected to enter a value

into the field for the movement.
Move Faces – Keyboard Shortcuts

Mirror and Scale Tools
198
Mirror
• Reflect selected parts across a symmetry plane.
• Instances are allowed.
199
Scale
Action Button
Temporarily disable snapping
Add to or remove from the selection
Copy a selected feature + drag

Reposition the tool or change its orientation
Reposition the tool or change its orientation Double click

Chain select faces Double- click or +Double-click
Exit editing mode
Exit the tool ESC
• Resize selected parts.
Boolean Parts
• Combine: when the combine is active, left-clicking any combination of parts
in the assembly will combine the selection.
200
• Subtract: when subtract is active, the targets are defined as the objects you
are wishing to modify. The tools are defined as the modifiers to these targets.
Keep tools option allowed.
• Intersect: when intersect is active, left clicking one part or multiple parts as
targets, or the part(s) you are wishing to modify. Next left clicking the tools
icon and select another intersecting part(s) as your tools or modifier(s). Keep
targets/tools/both allowed.
Action Button
Select Tools Tab
Add to or remove from

the selection
Exit tool Esc
Combine Subtract Intersect
201
Cut and Simplify Tools
Targets are defined as the parts you are performing the cut on. The plane, or cutting
plane, can be defined by selecting a face or feature based on existing geometry and
translating/rotating accordingly with the move tools.
Action Button
Add to or remove from the selection
Exit tool Esc
Simplify
• Imprints: finds and removes imprints such as scratches and trimmed points.
• Rounds: finds and removes any rounds (concave) or fillets (convex) in the
assembly. Find options and filtering.
• Holes: finds and removes holes and pockets. Find options.
• Plug finds holes and pockets and plugs them by filling the area with a new
part. Find options.
202
Imprints Rounds Holes Plug
Note: remove small fillets first, then larger fillets, then rounds
203
Simplify Tools - Partition Parts
• Partition geometry along a hole, a face
Mid-Surface and Fillet Tools
Action
Select a feature Click
Deselect a feature + Click
Add to the selection + Click
Execute the partition Click a selected (red) feature to preview and

edit it. Click again to partition it.
Accept the partition and exit
Delete the partition Delete or + Click
204
Midsurface
• Find and extract 2D sheets from single thickness thin solid geometry.
Action Button
Select thin solid Click
Extract mid surface Click
Restore original part Click
Add/remove from selection + Click
Exit tool Ecs
205
Fillets
Fillets tool can round edges. It supports fillets with a constant radius (not variable).
Chamfer tool can create beveled edges
206

Inspire Cast Final PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Inspire Cast Final PDF

Uploaded by

Copyright:

Available Formats

Contents

About this Book............................................................................................................. 4

Thanks, Altair University Team

learn, the more places you’ll go”

- Dr. Theodor Seuss Geisel

Dr. Matthias Goelke

Middle Ages to 1800

The 19th Century

Early 20th Century

Late 20th Century

(This chapter is entirely based on History of Metal Casting-http://www.metal-

• Fluidity, Slag formation

(K.G. Swift, J.D. Booker 1999,pg 336).

Pouring temperature: Pouring temperature is the temperature at which a given

tf = (V/A)(ℓs H)/ h(TM-To).

The temperature – distance profile is shown below

While designing a product a detailed communication and exchange of scientific and

Cooling curve of pure metals Crystallization of pure metal

Free energy – Temperature diagram

2.4 Niyama Criterion for Predicting Shrinkage

Micro-shrinkage porosity in aluminum casting was predicted by computer simulation

Simulation results of Niyama Criteria for V rod

The various parts of sand casting are described below:

The diagram shows different parts of sand-casting methods

The diagram shows a typical cast structure.

2.5.2 Investment Casting

Investment Casting of Turbine Blades

Advantages of Investment Casting:

Disadvantages of Investment Casting:

2.5.3 Die Casting

2.5.4 Gravity Die Casting

Motor Block Casting

2.5.5 High Pressure Die Casting

2.5.6 Low-Pressure Die Casting

2.5.7 Centrifugal Casting (Industrial)

True Centrifugal Casting Machine

Horizontal Centrifugal Force (F) = mV2/R, Where m= mass, V = velocity and R =

Semi Centrifugal Casting Method

2.6 Casting Components

2.6.2 Riser Casting /Feeder

A typical casting system showing seven elements

V = (2gh) where h is the height of sprue.

Let A1=Cross sectional area of entrance of sprue

A2 = Cross-sectional area of exit of sprue

h1 = pouring basin height

h2 = Sprue + pouring basin height.

So, the condition for no aspiration is A1 / A2 >=  (h2/h1)

Schematic diagram showing open riser and blind riser.

Riser design is very important because of the following reasons:

• An undersized riser could lead to shrinkage defects and ultimately a rejection

Necessary and enough conditions for riser design

• Necessary Condition: Vr > 3 Vsc

Vr= Volume of Riser and Vsc= Volume of Shrinkage

• Sufficient Condition triser > tc

triser , Solidification time of riser metal > tc , Solidification Time of Casting

• Location of Riser: Easy flow of liquid metal to the casting

• Use of insulating materials around the riser

2.6.3 Insulating or Exothermic Sleeve

sizes. An exothermic reaction is a chemical reaction that is accompanied by the

• Cost savings due to high foundry yields.

• Significant saving in energy and costly foundry inputs due to the

2.6.4 Overflow Risers (Cavity/Passages)

2.7 Pouring Techniques