Yes! We can perform air entrapment prediction and overcome by air entrapment simulation using ADSTEFAN casting simulation software. Here is how we can do

In the world of casting, air entrapment is one of the common challenges for foundry engineers. Tiny air pockets that get trapped inside molten metal during mold filling often lead to blowholes, leak failure, and rejections. But the good news is – with today’s advanced casting simulation tools likes ADSTEFAN, we can predict air entrapment before it happens and overcome it using air entrapment simulation.

Here’s how we can approach it, step by step.

The Challenge:

On the shop floor, air entrapment often goes unnoticed until defects show up in machining or inspection. The results are:

1. Porosity
2. Leading to casting rejections.
3. Failure in leak test
4. Poor aesthetic look
5. Unnecessary rework and scrap costs
6. Delays in product development

Traditionally, solving these problems meant trial-and-error, redesigning gating, and re-pouring until the defect disappeared – a costly process

Our solution:

Step 1: Air Entrapment Prediction

Using ADSTEFAN casting simulation software, we can analyse the mold filling process virtually. The simulation will predict:

1. Locations where air was likely to be trapped
2. Turbulent metal flow zones
3. Venting inefficiencies in the gating design
4. This step gives us a clear prediction of air entrapment – information that would have taken multiple real-life trials to uncover.

Step 2: Air Entrapment Simulation for Solutions

Once we identified the problem areas, we can use ADSTEFAN casting simulation to check improvements virtually:

1. Modified gating design to ensure smoother filling
2. Optimized venting paths for better air escape
3. Adjusted pouring velocity to minimize turbulence

The Results: Defect-Free Castings

After implementing the optimized gating simulation-driven changes, we can achieve:

1. Significant reduction in porosity and blowholes
2. Reliable, leak-proof castings for critical applications
3. Lower rejection and rework costs
4. Faster product development cycle

Most importantly, the foundry team can make confidently data-driven design decisions rather than relying on guesswork.

Why It Matters

By combining air entrapment prediction with ADSTEFAN Casting simulation software, foundries can:

1. Detect and solve defects virtually
2. Save time, money, and material waste
3. Deliver high-quality castings consistently
4. Stay competitive with faster development cycles

Conclusion

Yes, it is absolutely possible to predict and overcome air entrapment – not by trial-and-error, but by using ADSTEFAN simulation software as a smart engineering tool. By taking informed decision rather than guess work reduces shop floor trails with defect-free castings, satisfied customers, and improved profitability.

Simulation is not just about predicting defects – it’s about preventing them before they ever happen.