Cast Iron quality is determined decisively by the applied melting practice, metal treatment and metallurgy. The prediction of feeding and structure formation of cast irons requires an accurate consideration of the microscopic phase separation, the foundries actual melt analysis and the type and effect of melt inoculation. The MAGMAiron module uses a microscopic kinetic growth model, which predicts the solidification sequence of cast iron alloys. Based on the alloy composition and the applied metallurgy MAGMAiron predicts the type and amount of graphite (grey, ductile or compacted iron) formed and gives an accurate simulation of competing graphite expansion and solidification contraction forces through which shrinkage and porosity are determined. This also allows the prediction of the final microstructures and mechanical properties in the casting.

MAGMAiron supports the foundryman by:

• determining the effect of any risering and gating system design on the casting quality
• removal or adjustment of features such as chill
• provides "maps" for the variation in mechanical properties through out the casting
• supports improved inoculation treatment in relation to alloy composition