In this study the determinations of melt quality was carried out by thermal analysis of ductile iron. The aim of the study was to determine the limits of feederless casting after the determination of inoculation quality in cast iron. Production method of pouring into a sand mold in the entirety and without using feeder systems has been investigated. Forms of the solidification and volume change have been investigated with simulation program as functions of inoculation quality, type of resin in the mold and mold rigidity. Results of the analysis have been compared with the results of experimental iron casting.

In this study, 1.2333 cold work tool steel and cast iron (GG 25) were simultaneously melted in dierent furnaces to fabricate composite die mold used in sheet metal forming industry. To enhance the metallurgical bond between two components of composite part, the pouring temperature of cast iron was assessed just above the solidus temperature, then metallurgically prepared cast iron was poured on to the cast tool steel. The temperature and casting parameters were monitored and simulated. Experimental and simulation results were compared, nally the optimum parameters and casting route were revealed.

High-pressure die casting oers reduced costs due to its small tolerances and smooth surface nish. Casting parts produced are consumed by the automotive industry in millions. In this study, the use of computer aided engineering applications on design of high-pressure die-casting was studied. The inuence of casting process steps in die design was studied and analyzed. The casting simulation software was used to improve design and solve problems. By using the simulation software in analyses of die design, the nal design was reached in a few hours and thus the design process of pre-production was shortened and mold production was carried out with no revision on die material. Radiographic test was applied on the casting parts and the result shows good correlation between simulations of solidication result data. Also the results proved that the application of squeeze pressure in the intensication phase of high-pressure die casting process could be examined in the casting simulation.

In this study, the types and possible causes of the dart defect, which is one of the surface defects that are frequently encountered in foundries, has been examined. As a case, a gearbox part with a high scrap rate of dart defect is considered. First of all, the parameters (mechanical properties of the mold sand, casting temperature, etc.) that are effective in the formation of the dart defect have been checked. According to the outputs of the Magmasoft © Simulation software, in order to prevent the cause of the dart defect in the part made of EN-GJL 300 material, it was observed that the runner ingates did not work in balance as a result of faulty in runner design. The gating system was redesigned with the basic approaches of fluid mechanics, and with the simulation made before the application on pattern, a significant improvement was observed compared to the outputs of the first simulation study. It has been seen that the root cause of the dart defect, which is generally known as sand expansion and the solution of which is sought in the sand parameters, may also be caused by the runner system. By evaluating the general literature and process control results with the simulation software result outputs, the cause of the dart defect was determined and the scrap rate of the part has been reduced by eliminating this defect type.