The simulation was able to show that the pores are filling-related. The position and dimensions of one rib resulted in splashing melt and air subsequently being entrapped.
The introduction of systematic changes in both the component design and the gating design of the die and the virtual analysis of these design changes helped to prevent the melt from directly splashing through the rib, thus eliminating the associated air entrapments.
Thanks to the communication between foundryman and designer based on the simulation results and the resulting measures, it was possible to completely eliminate the problem.
If you are interested in learning more about the numerous options for evaluating simulation results and getting to know the possibilities for methodologically evaluating casting processes in the run-up to production, attend the seminar “Evaluation of Simulation Results with MAGMASOFT®” (available upon request). The intended audience of this event are foundry managers and/or executives and experts from design, quality and purchasing departments.