See some of the most relevant publications about MAGMA applications and developments.

Simulation Evolves to Autonomous Optimization

Today’s requirements on the development of a casting and the corresponding metal casting process demand methodologies and tools which allow a maximization of process robustness and profitability at the earliest possible point in time. Opposed to real-world trials, autonomous optimization using simulation tools provides significantly more flexibility.

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Design Optimization of Heat Treatment Support Frames for Aluminum Alloy Structural Cast Parts Using Virtual Experimentation

The work shows how heat treatment support frames can be optimized by virtual experimentation using an integrated simulation approach. A unified creep material model is applied to model the distortion of an industrial thin-walled aluminium structural die cast part. The changing part deformation during the entire casting and heat treatment process as well as the effects of different supporting frame concepts on the distortion will be discussed. The predicted part deformation is compared for different supporting frame designs and is quantitatively assessed using a virtual 6-point (Reference Point System) measurement device.

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Heat Treatment of Steels – Optimization of Microstructures, Mechanical Properties, Stresses and Distortions by Virtual Optimization

Cast steels are characterized by a large variety of mechanical properties and microstructures after the heat treatment process in dependence on their final application. Process variations like differences in austenitization time and temperature, cooling conditions and chemical compositions play the significant role for high quality cast products. Process simulation with MAGMASOFT® is able to predict phase contents as well as mechanical properties including theses process variations in heat treatment and supports therefore a robust industrial heat treatment process design. Industrial examples for microstructure optimization of cast steels for a chain link will be given within the paper.

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Process Optimization for an Energy Efficient Heat Treatment of ADI

Austempered ductile iron (ADI) materials show a good combination of mechanical properties, with high tensile strength levels (800 - 1600 MPa) and an elongation at fracture of up to 10%. Due to its high fracture toughness as well as high fatigue resistance, ADI is a very attractive material group for applications under cyclic loads. However, the material properties are very sensitive to the applied process conditions during heat treatment. The basis for a substantial increase in the application of ADI materials in the industry requires the establishment of a predictable and robust process design. Here, an integrated process simulation of the heat treatment process coupled to required information about the as-cast quality of the component would aid in understanding process dependencies and defining a robust process window.

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Reduction of Oxide Inclusions in Aluminum Cylinder Heads through Virtual Design of Experiments

It will be shown in this paper that virtual design of experiments (vDOEs) are leading to optimized gating designs and process parameters resulting in a significant reduction of oxides in castings. The experiments supported by simulation were accompanied and validated by high-speed video technology and the PREFIL-measurement technology.

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