This paper investigates the casting defects of a stainless steel pump impeller manufactured through the sand casting process. The material characterization of austenitic steel AISI 316L was initially carried out, which examined the chemical composition of the casting and its microstructure. The next step was to determine the cause of the casting defects using numerical simulations. The numerical simulations were performed using ProCAST software (Version 18.0). Initial results of the filling and solidification simulations were conducted using the parameters employed in the actual casting process, revealing casting defects in corresponding locations. The casting process was subsequently modified to achieve improved results. This involved reconstructing the gating system, redesigning the riser, and incorporating a cylindrical chiller. The results show that the modified casting process significantly reduces the occurrence of defects in the final product. The study provides useful insights into the analysis and modification of the casting process for stainless steel pump impellers produced through sand casting. The results can help improve the quality of such products and reduce production costs associated with casting defects.

The paper presents the application of 3D optical scanning and numerical simulation in the development of a high-pressure die casting process for a differential transmission cover. The geometry of the existing casting was digitized using a 3D optical scanner, followed by reconstruction of the CAD model using reverse engineering. Based on the reconstructed geometry, the gating system and overflow elements were defined, and a numerical model of the die casting process was developed. Numerical analysis was performed using the ProCAST software package, with the filling of the die cavity, solidification of the molten metal, temperature distribution, and the potential occurrence of characteristic casting defects, including air entrainment and shrinkage porosity, being analyzed. The simulation results showed favorable filling and solidification behavior, with only localized areas exhibiting an increased potential for shrinkage porosity. The conducted research demonstrates the applicability of combining 3D scanning, reverse engineering, and numerical simulation as an effective approach to the development and optimization of die casting processes.