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For the first time ever, the paper presents an original scientifically informed approach to manufacturing process design for magnesium alloy casting of large body parts using combined moulds (a permanent mould with an internal sand core). This approach involves solving a system of problems to ensure directional solidification and a steady feeding rate. To solve these problems at each stage of mould filling and casting formation, we used methods of foundry hydraulics and thermal theory of casting to derive expressions for computing the necessary manufacturing parameters, from the pouring temperature to the duration of keeping the finished casting in the mould. We combined these computational techniques into a single software package, which was successfully tested in practice at the JSC Moscow Mechanical Engineering Plant AVANGARD and Public stock company “Dolgoprudny Research Production Enterprise” while manufacturing surface-to-air missile compartments for the S -400 Triumf and Buk-M3 anti-aircraft weapon systems.

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