At the beginning of the optimization, the experts used MAGMASOFT® to understand the problem observed in the original layout. The tendency to form shrinkage porosity in the feeder neck area could be confirmed. However, eliminating the problems by simply making adjustments to the feeder or feeder neck was not possible, due to the technical constraints on the pattern.
Therefore, further changes in the casting layout were necessary. Based on the experience of the SSF experts, the impact of rotating the component by 45° in the mold was assessed with the help of MAGMASOFT®. To rotate the parts, the feeders had to be changed to a spherical shape, something that SSF had already been using successfully for other castings. These modifications helped to shift the porosity away from the critical area. However, the change also had a negative impact on the mold filling. An increase in turbulence during filling was observed, which led to a higher risk of sand inclusions.