Leaks in casting for valves and pumps are a major cause of casting rejections. Repairs, extra NDE and heat treatments increase part cost. Major repairs or worse, producing a new casting, has major impact on project or turn-around schedule.
Solidification simulations prior to pattern preparation, moulding and pouring is a known tool to improve casting quality, and especially the Niyama criterion has been shown to predict micro and macro shrinkage with certainty. . Most established foundries have and use casting simulation software and can do these simulations. Outcome varies however due to lack of alloy datasets and the different skill levels of foundry engineers
In MTI project 175-06 the benchmark metals dataset was developed for 11 alloys. Additional tools for foundry engineer qualification were developed with a template valve body casting.
In this 2025 project proposal similar benchmark dataset development for alloys not included in the 2006 project is proposed: Super Duplex Stainless Steel Z-100 and 2507, CA6NM, CK3MCuN, 600, 200, 59, LC 25Cr-35Ni-Nb, etc.