This guest contribution on Innovation Intelligence is written by Håkan Fransson, Technical Manager – Simulation at NovaCast Systems AB. NovaFlow&Solid 6.0 by NovaCast is a mold filling and solidification simulation package based on advanced fluid flow and heat transfer theories and is available through the Altair Partner Alliance.
Historically, foundries have used too high of casting temperatures during high pressure die casting simulations. Many foundries believe there is a minimal temperature drop (~ 20 degrees) from the melting furnace to the filling of the part. Running a simulation with too high of a casting temperature will result in an incorrect simulation of the cold flow and a different temperature gradient which will cause the porosity prediction to be slightly off. This can result in cold joints, cracks on the surface of the casting, or increased porosity.