Metal Casting Development publishes casting engineering insights, technical articles, engineering observations, and case-based insights focused on casting process design, simulation, gating and feeding systems, metallurgy, defect analysis, melt quality, and production-focused foundry engineering.
This section is intended for engineers, foundries, OEMs, and manufacturing teams looking beyond generic casting advice toward practical process understanding, manufacturability, and production performance.
Casting Process Design
Casting performance is heavily influenced by decisions made long before production begins. Articles in this section focus on gating and feeding design, filling behavior, process robustness, manufacturability, tooling considerations, and the engineering decisions that influence casting quality, yield, and long-term production stability.
Casting Simulation & Process Validation
Simulation is a powerful engineering tool when used to support real manufacturing decisions. Articles in this section explore mold filling behavior, solidification, process optimization, defect prediction, simulation methodology, and the relationship between virtual analysis and production reality. Particular emphasis is placed on developing robust casting processes rather than simply generating simulation results.
Metallurgy & Melt Quality
Mechanical performance begins with metallurgy. Articles in this section cover alloy behavior, melt treatment, grain refinement, modification practices, hydrogen control, quality index analysis, and the metallurgical factors that influence casting properties, consistency, and process capability. The focus is understanding how metallurgy influences both casting quality and achievable production performance.
Casting Defects & Failure Analysis
Casting defects are rarely the result of a single variable. Articles in this section examine the interaction between design, metallurgy, process control, mold behavior, and manufacturing variation to identify the root causes of defects and performance issues. Topics include porosity, inclusions, oxide-related defects, dimensional variation, mechanical property shortfalls, and production troubleshooting.
Casting Engineering Case Studies
Every casting program presents unique technical challenges. This section contains project observations, engineering lessons, development experiences, and practical insights gained from real-world casting programs. Topics may include new product launch support, process development, supplier qualification, simulation-driven improvements, production stabilization, and lessons learned during program execution.
