Aachen

March 2020

MAGMATIP 7
FILLING RESULTS

This MAGMATIP explains the filling results.

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TABLE OF CONTENTS

1 FILLING RESULTS ........................................................................................................ 1

2 CONTACT ...................................................................................................................... 5
1 FILLING RESULTS
For the different processes (sand mold, permanent mold and high pressure die casting), you
can evaluate the following filling results, provided you have previously defined (requested)
them in the result definitions:

Figure 1: List of the filling results: sand mold casting (left), permanent mold casting (center), high
pressure die casting (right)

'Temperature' This result shows the temperature distribution within the selected
material group during pouring/filling at a particular time. Temperatures
are shown in the color scale in °C.

'Velocity' This result indicates the velocities that exist at a particular time within
the melt. Velocities are shown in the color scale in m/s.

'Pressure' Pressure distribution: This result shows the pressures in the melt
during filling at a particular time. Pressures are shown in the color scale
in mbar (in bar for high pressure die casting).

'Fraction Liquid' Percentage of liquid phase: This result indicates the local percentage
of liquid melt at a particular point in time during filling. This result will

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 only be displayed once the melt temperature has fallen below the
liquidus temperature during the filling process. With this result, you can
identify pre-solidified areas. The 'Fraction Liquid' value is shown in % in
the color scale.

'Fraction Solid' Percentage of solid phase: This result indicates the local percentage of
solidified melt at a particular point in time during filling. This result will
only be displayed once the melt temperature has fallen below the
liquidus temperature during the filling process. With this result, you can
identify pre-solidified areas. The 'Fraction Solid' value is shown in % in
the color scale.

'Tracer' Particles in the melt: This result is automatically loaded as an

animation, thus allowing you to observe the movement of particles in
the melt. The standard tracer particles have no mass and thus indicate
the movement of the melt flow. You may, however, also assign a
density and a diameter to the particles before the simulation to allow
the tracer particles to move in the melt flow based on their properties.
This also allows you to track both air and sand particles in the melt
flow. In addition, you can choose from various presentation options,
such as 'Age', 'Path Length' or 'Pressure', etc. (please note: The
presentation options vary based on the selected process mode). Tracer
particles need to be defined beforehand in the Geometry Perspective.

'Air Pressure' The 'Air Pressure' result indicates the air pressure in the areas not yet
filled. Depending on the number of results defined, with this result you
can clearly see how the air is displaced by the melt and how the air
pressure in the air inclusions keeps slowly rising. Since, at 100 % filled,
there are no more air inclusions, no corresponding result is found in the
result folder. For HPDC, the air pressure is indicated in bar, whereas
for sand casting, it is given in mbar.

'Max Air Pressure' Maximum air pressure: This result indicates the maximum air pressure
occurring during the filling process in a certain area (mesh element).
These pressures do not necessarily represent the location of air at the
end of filling! For HPDC, the air pressure is indicated in bar, whereas
for sand casting, it is given in mbar.

'Air Entrapment'
(sand / permanent
mold casting only) Air entrapments: This result shows the percentage of entrapped air in
the melt. It is calculated from the point in time when an air inclusion
(unfilled areas = 'Air Pressure') is filled with melt. This air then moves
along with the melt flow, the air fraction per mesh element thus
continuously decreasing. This process is similar to a drop of ink that
keeps dissolving more and more in water. For a quantitative evaluation
of this result, you need to consider if previously, at the point in time "air

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 inclusion is filled", a high or a low air pressure prevailed in a given
area. Air entrapments are indicated in %.

'Entrapped Air Mass'

(HPDC only) Mass of entrapped air: This result indicates the mass of the air
entrapped in the melt. This result allows you to trace the air movement
through the cavity during the filling process and see the final position of
the entrapped air at the end of filling. As air is often entrapped inside a
casting, it makes sense to hide melt areas with smaller air fractions by
using the 'X-Ray' function. The value (µg) starting at which you choose
to show/hide the air mass certainly depends on the individual quality
criteria for the casting. The entrapped air is shown in µg per mesh
element; therefore, major variations in your mesh may also lead to
great variations in the result display. The result "100 % filled" shows
the complete remaining air mass.

'Intensification
Air Entrapment'
(HPDC only) This result indicates the volume fraction of entrapped air with
consideration of the intensification pressure. The locally entrapped air
('Entrapped Air Mass') is compressed by the intensification pressure
here. You thus know the volume of the entrapped air and can indicate
by what percentage a certain mesh element is filled with air. This
means that, for the same mass of air, an increase of the intensification
pressure will result in lower percentages and vice versa. This
percentage is indicated by the result 'Intensification Air Entrapment'. As
the value for the intensification pressure is defined in the solidification
phase and is also stored there (from a software point-of-view), it is
currently imperative to calculate the solidification to obtain the result
'Intensification Air Entrapment'.

Caution:
To be able to calculate air pressure-related results, you need to have previously specified
corresponding vents ('Vents') in the Geometry Perspective.

'Material Trace' Melt path: This result shows from which gate each area of the casting
is filled. That is, melt flowing through gate 1 is, for example, shown in
red, whereas the melt flowing through gate 2 is, for example, shown in
white. Based on the resulting color mixing in the casting, you can see
from which gate the melt has been fed in the different casting areas.
Areas with very similar colors indicate a minor mixing of the melt,
whereas areas with distinctly different colors in the transition zone
indicate a strong mixing of the melt. To obtain this result, you need to
assign different material IDs to the gates in the Geometry Perspective
beforehand.

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'Air Contact' This result shows how long the melt had contact with air. Elements with
high values show the biggest danger of oxide skin formation. This
result is indicated in seconds.

'Material Age' This result shows the age of the melt in each filled element. Material
coming from the inlet always starts with a material age of zero. The
cast material age is given in seconds.

'Flow Length' Cast length from the inlet: This result shows the flow length of the melt
from the inlet. The flow length is indicated in mm.

'Wall Contact' This result shows how long the melt had contact with the mold. The
wall contact is shown in seconds.

'Cast Length' Cast length from the gate: This result shows the flow length of the melt
from the gate. The flow length is indicated in mm.

'Filling Temperature' This result indicates at which temperature a cell is filled for the first
time. The filling temperature is shown in °C.

'Filling Time' This result indicates after how much time a cell is filled with melt for the
first time. The filling time is indicated in seconds.

'Filling Velocity' This result indicates at which velocity a cell is filled for the first time.
The filling velocity is shown in m/s.

'Mold Erosion' This result shows the erosion on the mold surface caused by an
excessively high velocity of the melt. Before a result can be written, first
a critical velocity of the melt and time need to be exceeded. A "unitless"
value can then be calculated, taking into account the flow direction. In
the material dataset of the mold material, you can adjust the limits for
time and velocity. This result can be shown both on the mold and on
the melt.

'Sand Inclusion:
Area Fraction'
(sand casting only) Area fraction of sand inclusions: This result is only shown at the surface
and thus gives you an impression of where you can expect surface
defects caused by sand inclusions.

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2 CONTACT
If you have any questions, please contact us.

MAGMA Gießereitechnologie GmbH MAGMA Engineering (Suzhou) Co., Ltd.

Kackertstr. 11 Room 1515 CIQ Tower
52072 Aachen, Germany No. 98 Suhui Road, Suzhou Industrial Park
Phone: +49 241 889010 Jiangsu Province, 215021 China
Fax: +49 241 8890160 Phone: +86 512 62725820
info@magmasoft.de Fax: +86 512 62725825
www.magmasoft.de info@magmasoft-china.com
www.magmasoft.com www.magmasoft-china.com

MAGMA Engineering Asia-Pacific Pte Ltd. MAGMA Engineering Korea Co., Ltd.
25 International Business Park Suite 902, Hyundai 41 Tower
#02-24/25 German Centre 917-9 Mokdong, Yangchun-gu
609916 Singapore Seoul 158-723, Korea
Phone: +65 65643435 Phone: +82 2 21683575
Fax: +65 65640665 Fax: +82 2 21683585
info@magmasoft.com.sg info@magmasoft.co.kr
www.magmasoft.com.sg www.magmasoft.co.kr

MAGMA Foundry Technologies, Inc. MAGMA Engenharia do Brasil Ltda.

10 N. Martingale Road, Suite 425 Alexandre Dumas, 1708, 1st floor
Schaumburg, Illinois 60173, USA 04717-004 São Paulo, SP
Phone: +1 847 9691001 Brasil
Fax: +1 847 9691003 Phone: +55 11 5535 1381
info@magmasoft.com Fax: +55 11 5535 1381
www.magmasoft.com magma@magmasoft.com.br

MAGMA Bilişim ve Teknoloji Hizmetleri MAGMA Engineering Branch Office India

Ltd.Şti. 2nd floor Aparajita Arcade,
Kuzguncuk Mah. Paşalimanı Cad. Flat no. # 3-5-900/1, Opp: Pantaloons Store,
Boğaziçi Apt. No: 112/B D:1 Himayath Nagar Main Road, Hyderabad - 500
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Fax: +90 216 557 5026 Fax: +91 40 66636517
info@magmasoft.com.tr info@magmasoft.co.in
www.magmasoft.com.tr www.magmasoft.co.in

MAGMA Gießereitechnologie GmbH

K Vinici 1256, studio 8
53002 Pardubice, Czech Republic
Phone: +42 0773 154664
info@magmasoft.cz
www.magmasoft.de