Unlike the aluminum alloys, the main problems with die casting magnesium alloys are not related to solder. Since magnesium alloys solidify much more rapidly, proper filling of the die cavity and prevention of cold flow defects are the primary concern of the die caster. Typically magnesium alloys are cast at much higher gate velocities than aluminum alloys. Since it is not as aggressive towards steel as molten aluminum, it may be cast in hot chamber and cold chamber machines.

Castle is the right tool for simulating Mg die casting:

-At those speed rate the metal doesn’t present an united flow front but it is crushed in many minute droplets which are composed of both metal and air. What is filling up the die is not simply an alloy but an emulsion of metal and air which has proprieties (viscosity, density etc) different from the metal itself. Castle is a dual phase (metal and air) simulation software and it is able to predict properly the location and the amount of entrapped air and to suggest how to optimize the die design for vacuum and venting evacuation systems. In Castle the single mesh cell is filled up by a mixture of both metal and air by increasing significantly the accuracy level of gas porosity prediction;

-Since magnesium solidifies much faster than other alloys it is very important to consider the rheology of the metal. Castle calculates the change of viscosity and the metal solidification also during the filling phase in a very limited temperature range. It makes the results much more accurate in terms of possible issues detection (i.e. cold slugs or incomplete filling) and temperature distribution visualization.


-Full 3D CAD capabilities

-Model preparation and setup for the calculation in under a minute

-Multiprocessing and cloud computing compatible

-Dual Phase simulation: metal pulverization, spray effect and micro air entrapments detected.

-Vacuum and vent effects calculation

-Interactive practical suggestions


Discover your suitable solution package

-Hybrid Mesh Approach > read more

-Process Optimization > read more

-Fast Runners simulation > read more

-Filling and solidification analyses > read more


Hardware suggestions

CPU: Processor Intel® Xeon® E5-2609 v2 (quad-core HT, 2,5 GHz, 10 MB) RAM: 16 Gb DDR3 with ECC RDIMM a 1866MHz Graphic card: NVIDIA® Quadro® K2000 2 GB or similar (alternatively: NVidia GeForce GTX 670) HDD: 1TB 3.5inch (7200 RPM) SATA / Alternatively: 1 SSD da 128 Gb (OS + Programs) + HDD SATA 1Gb (Data)