CH.

8: DATABASES 8-1

DATABASES / 'database'

Table of Contents

8 Databases..................................................................................................................... 8-5
8.1 Data Administration in MAGMAdata – Overview.......................................... 8-6
8.1.1 Databases in MAGMAdata.................................................................... 8-6
8.1.2 The MAGMAdata Interface ................................................................... 8-7
8.1.3 General Database Functions .............................................................. 8-11
View Data / 'View'................................................................................ 8-11
Create New Data / 'New' ..................................................................... 8-11
Modify Data / 'Edit' .............................................................................. 8-12
Copy Data / 'Copy' .............................................................................. 8-12
Delete Data / 'Delete' .......................................................................... 8-13
Delete All Data / 'Delete All' ................................................................ 8-13
Assign Information to a Dataset / 'Global Information' ........................ 8-13
'Re-Load'................................................................................. 8-14
'Load Backup'.......................................................................... 8-14
'Save' ...................................................................................... 8-15
'Import Picture' ........................................................................ 8-15
'Close' ..................................................................................... 8-15
'Edit' ........................................................................................ 8-16
'Short Description' ................................................................... 8-16
'Groups'................................................................................... 8-16
'Status' / 'Ready to use'........................................................... 8-16
'Protection' .............................................................................. 8-17
'Memo'..................................................................................... 8-17
Import Data from Databases / 'Import' ................................................ 8-18
Import Data from a Different Project's Database / 'Import From Other
8-2 MAGMASOFT® 4.4 MANUAL

Project' ................................................................................................ 8-19

Import Data from Release 2 / 'Import From Release 2'....................... 8-19
Recreate Database Index / 'Recreate Index'....................................... 8-22
'Delete Backup Files'........................................................................... 8-22
Database Archive / 'Pack/Unpack Database Archive'......................... 8-22
'Convert Project Files' ......................................................................... 8-23
Activate Windows / 'Windows'............................................................. 8-24
8.2 Material Properties / 'Material'...................................................................... 8-25
8.2.1 Melt / 'Cast Alloy'................................................................................. 8-25
'General Parameters' .......................................................................... 8-26
Thermal Conductivity / 'Lambda' ......................................................... 8-28
Density / 'Rho' ..................................................................................... 8-32
Specific Heat Capacity / 'Cp' ............................................................... 8-33
Fraction Solid / 'fs' ............................................................................... 8-34
Specific Heat Content / 'Rho*Cp (view only)' ...................................... 8-35
'Flow Properties'.................................................................................. 8-36
Flow Properties – Newtonian Rheology Model / 'Rheology'................ 8-37
'Erosion Properties' ............................................................................. 8-39
'Material Composition' ......................................................................... 8-40
'Material Properties'............................................................................. 8-41
Material Datasets in the 'MAGMA' Database ...................................... 8-42
Materials for Cast Alloys in the 'MAGMA' Database ........................... 8-43
8.2.2 'Core' ................................................................................................... 8-44
Materials for Cores in the 'MAGMA' Database.................................... 8-45
8.2.3 'Sand-Mold' ......................................................................................... 8-45
Materials for Sand Molds in the 'MAGMA' Database .......................... 8-45
8.2.4 'Insulation' ........................................................................................... 8-46
8.2.5 'Chill'.................................................................................................... 8-46
8.2.6 'Permanent-Mold' ................................................................................ 8-47
CH. 8: DATABASES 8-3

8.2.7 'Cooling'............................................................................................... 8-47

8.2.8 User-Defined Group 1 / 'User-Defined 1' ............................................ 8-48
8.2.9 User-Defined Group 2 / 'User-Defined 2' ............................................ 8-48
8.3 Internal Heat Transfers / 'HTC' ..................................................................... 8-49
8.3.1 Internal HTC Datasets in the 'MAGMA' Database .............................. 8-50
8.3.2 Constant Heat Transfer / 'Constant' .................................................... 8-56
Datasets in the 'MAGMA' Database.................................................... 8-56
8.3.3 Temperature Dependent Heat Transfer / 'Temperature Dependent' .. 8-57
Datasets in the 'MAGMA' Database.................................................... 8-57
8.3.4 Time Dependent Heat Transfer / 'Time Dependent'............................ 8-60
8.3.5 Coating Heat Transfer / 'Coating' ........................................................ 8-61
Thickness / 'Coating Defaults' ............................................................. 8-62
Thermal Conductivity / 'Lambda' ......................................................... 8-62
Effective HTC / 'Effective HTC (view only)' ......................................... 8-64
8.3.6 Cooling Channel Heat Transfer / 'Cooling Channel – Standard' ......... 8-64
'Cooling Channel Defaults' .................................................................. 8-65
Further Properties of the Cooling Fluid ............................................... 8-65
Effective HTC / 'Effective HTC (view only)' ......................................... 8-67
8.4 External Boundaries / 'Boundary' ................................................................ 8-67
8.4.1 External Boundary Datasets in the 'MAGMA' Database ..................... 8-68
8.4.2 Radiation and Convection / 'Radiation and Convection' ..................... 8-70
List of Datasets in the 'MAGMA' Database ......................................... 8-71
Environment Temperature / 'Defaults'................................................. 8-71
Radiation Coefficient / 'Radiation' ....................................................... 8-72
Heat Transfer Coefficient / 'Convection'.............................................. 8-73
Effective HTC / 'Effective HTC (view only)' ......................................... 8-74
8.4.3 Heat Transfer Coefficient / 'HTC' ........................................................ 8-74
Datasets in the 'MAGMA' Database.................................................... 8-75
Environment Temperature / 'Defaults'................................................. 8-75
8-4 MAGMASOFT® 4.4 MANUAL

Heat Transfer Coefficient as a Function of Temperature / 'HTC' ........ 8-76

8.5 Filter Data / 'Filter' ......................................................................................... 8-77
8.5.1 Filter Datasets in the 'MAGMA' Database........................................... 8-77
8.5.2 'Filter Parameters' ............................................................................... 8-78
Pressure Loss in Main Flow Direction / 'Pressure loss in s-Direction'. 8-83
Pressure Loss in Cross Flow Direction / 'Pressure loss in t-Direction' 8-84
8.5.3 Foam Filters / 'Foam'........................................................................... 8-86
Foam Filter Datasets in the 'MAGMA' Database................................. 8-86
8.5.4 Sieve Filters / 'Sieve' ........................................................................... 8-87
8.5.5 Flow-Rite Pressed Filters / 'Flow-Rite' ................................................ 8-89
Pressed (Flow-Rite) Filter Datasets in the 'MAGMA' Database .......... 8-89
8.6 Geometry Data / 'Geometry' ......................................................................... 8-90
8.6.1 Feeder Geometry Datasets in the 'MAGMA' Database....................... 8-90
8.6.2 View Geometry / 'Geometry (view only)' ............................................. 8-91
8.6.3 Command Files / 'Cmd-File' ................................................................ 8-91
8.6.4 Import Geometry as GEO File / 'Import Geometry' ............................. 8-92
8.6.5 Import Geometry as Command File / 'Import Cmd–File' ..................... 8-95
8.7 Microstructure Data / 'Real Reality Realizer'............................................... 8-97
8.7.1 Defining Dendrite Arm Spacings / 'Samples'....................................... 8-98
8.7.2 Defining Alloy Constant / 'Alloy Constant' ......................................... 8-100
8.8 Table of Figures........................................................................................... 8-101
CH. 8: DATABASES 8-5

8 Databases

MAGMASOFT® supports the work on your casting systems using several databases. These con-
tain e.g. information like thermophysical data, data about filters and information about certain el-
ements of the casting system (feeders, standard geometries etc.). Whenever you need data you
can invoke them from different places in the program.

By creating and modifying data, you can adjust the databases to your individual needs. There are
also safety mechanisms in order to avoid data changes by mistake.

The first chapter (Î Ch. 8.1, page 8-6) is a general introduction to the usage of the databases.
You will find information on administrating the data. In particular you will find answers to the fol-
lowing questions:

• Which information is stored in the database?

• Which meaning does the information have within the program?

• What are the differences between the databases?

• How can you store data in a database?

• How can you import data?

• How can you modify data?

After that you find a description of the available data types and their particular qualities:

• Material properties (Î Ch. 8.2, page 8-25)

• Internal heat transfers (Î Ch. 8.3, page 8-49)

• External boundaries (Î Ch. 8.4, page 8-67)

• Filter data (Î Ch. 8.5, page 8-77)

• Geometry data (Î Ch. 8.6, page 8-90)

• Microstructure pictures (Î Ch. 8.7, page 8-97)

! Irrespective of the type of data you are dealing with in the moment, you should always
read Ch. 8.1, page 8-6 pp carefully, as its contents are important for all types of data.
8-6 MAGMASOFT® 4.4 MANUAL

8.1 Data Administration in MAGMAdata – Overview

8.1.1 Databases in MAGMAdata

The first step for administrating data is always to select the database you want to work with. Pro-
ceed as follows to select a database:

Ö Open the main database window (Î Fig. 8-1, page 8-8) by choosing 'database' from the
MAGMASOFT® main interface.

Ö Open the menu 'Database' and select the desired database. The database 'MAGMA' is se-
lected as default.

MAGMASOFT® offers several databases. The databases have different access mechanisms and
are designed for different purposes accordingly. The datasets supported by MAGMASOFT® can
be stored in each database:
'MAGMA' The database 'MAGMA' is provided with MAGMASOFT®. 'MAGMA' is
accessible for all users of MAGMASOFT®. The data can be read only
and cannot be modified. The complete work with MAGMASOFT® is
based on the 'MAGMA' database. One important feature of data use
and administration in MAGMASOFT® is copying data from the 'MAG-
MA' database into one of the other three databases described in the fol-
lowing.
The MAGMA database contains data from various reputable sources
that are based on latest scientific methods and knowledge. We believe
that these are the best available data at time of publication. However,
MAGMA gives no guarantee about accuracy of the data and accepts no
liability for the consequences of their use.
You find the database 'MAGMA' in the directory '$MSLIBDIR / Mag-
maDB' (corresponding to '.../v4.x/lib/MagmaDB').
'Global' This database is accessible to all users of MAGMASOFT®. 'Global' is
free to be modified by every user. You should store those data to be
used by all users and projects in the database 'Global'. This database
is suitable for working in a group, because all users are supplied with
the same data.
You find the database 'Global' in the directory '$MSVARDIR / GlobalDB'
(corresponding to '.../v4.x/var/GlobalDB').
CH. 8: DATABASES 8-7

'User' The database 'User' is designed for a single user, and only that user has
unlimited acess to the data. Other users cannot read or edit data from
this database. You should store all data that you want to use alone here,
e.g. to test it before copying and releasing it to the 'Global' database.
The database 'User' is stored in the directory '.../MAGMAsoft/UserDB',
which you can find in the home directory of the corresponding user.
'Project' For each version that you add to a project you can create a database
'Project' to store data belonging to the project. Thus you can store all
data and settings with the project. This enables you to make data spec-
ifications for particular project versions. You can work only on the data-
base 'Project' that belongs to the currently selected version and project.
If you create a new version, data of the 'Project' database are automat-
ically taken from the version that forms the basis for the new version.
(Please refer also to Ch. 2.4, page 2-11 and Ch. 2.5, page 2-20 of this
manual for creating projects and versions.)
You find the database 'Project' in the directory of the corresponding ver-
sion (<home directory>/MAGMAsoft/<projectname>/<versionname>/
ProjectDB'.
External databases In addition to these four standard databases there is a functionality for
external databases. The corresponding access is controlled by a spe-
cial MAGMASOFT® license key. Please turn to MAGMA to receive
more information.

! The MAGMA database contains data from various reputable sources that are based on
latest scientific methods and knowledge. We believe that these are the best available
data at time of publication. However, MAGMA gives no guarantee about accuracy of
the data and accepts no liability for the consequences of their use. Please read the
latest release notes to get an update of the data.
Please contact our Customer Support Department if the database does not contain your
alloy or if you think that you have found mistakes in existing data.

8.1.2 The MAGMAdata Interface

You can invoke the data administration module, MAGMAdata, from the main menu of MAGMA-
SOFT® as well as from several windows within the program at places where the import of data
8-8 MAGMASOFT® 4.4 MANUAL

from the database is required. The latter usually takes place via a button labelled 'MAGMAdata...'.
Proceed as follows to invoke the data administration from the main menu:

Ö Choose the function 'database' in the main menu of MAGMASOFT®. The databases' main
window appears (Fig. 8-1).

Fig. 8-1: The main window of the MAGMASOFT® databases

The access to the different kinds of data and databases as well as the data import function is sup-
plied via the main menu of MAGMAdata:

• In the menu 'Database' you select the database you want to work with. The selected database
is shown in top middle of the window. In Fig. 8-1, e.g., the 'Global' database is chosen. See
Ch. 8.1.1, page 8-6 for further information on the different databases.
CH. 8: DATABASES 8-9

• In the menu 'Dataset' you select the data type ('Material', 'Filter', 'HTC' etc.) you want to work
with. See Ch. 8.2, page 8-25 to Ch. 8.7, page 8-97 for further information about these data.

• The function 'Import' allows you to import datasets from any database into the currently se-
lected database.

• The menu 'Utilities' supplies you with several help functions. It allows e.g. to recreate the index
of the database and to convert project files to different formats.

• Use the 'Windows' menu to jump between open windows of the database. MAGMAdata al-
lows you to open as many 'Edit' and 'View' windows as you like at the same time.

! All menus that you invoke from the main menu of the main window can be placed at ran-
dom on the screen. This can be useful if you open several data windows, which overlay
the main window. In this case you would always have to activate the main window if you
wanted to invoke functions from its menu bar. Proceed as follows to change the position
of menus:
Ö Open the menu that you want to move on the screen.
Ö Press and hold the middle mouse button and drag the menu to the required position.
It should be fully visible. Release the middle mouse button to drop the menu.

In the list in the left part of the window you find the datasets of the currently selected data type
that the selected database contains. The name of the dataset is shown above the list. In Fig. 8-1,
the type 'Material' is shown.

All commands that you need to create or modify data are available in the 'Commands' menu. De-
pending on the state of protection of the data, these functions are only partially available. Active
commands are shown in bold letters.
'New' Creates a new dataset.
'Delete' Deletes the dataset that is selected in the list on the left side.
'Delete All' Deletes all datasets of the current data type ('Material', 'HTC', 'Boundary', 'Fil-
ter' or 'Geometry').
Using the button 'Group Filter' you can limit the display of the delete process
to a subgroup of the data. Depending on the setting under 'Group Filter', all
datasets of the currently selected subgroup are deleted with the 'Delete All'
function.
'Copy' Copies the selected dataset.
8-10 MAGMASOFT® 4.4 MANUAL

The dataset selected in the list is copied (duplicated) and given a new name
to be entered by you.
Use this function to create a dataset with properties similar to the selected
dataset. Instead of creating all data anew, the data are copied and changed
as required at few points only.
'View' You can view the properties of the selected dataset but not modify them.
'Edit' You can modify the properties of the selected dataset. You can also invoke
this command by selecting the desired dataset via a double click with the left
mouse button. Please note that the datasets of the MAGMA database cannot
be edited. The 'Edit' function is not available for these datasets accordingly.
These functions are explained in detail in Ch. 8.1.3, page 8-11 pp.

Most data belong to one or more groups. For example, data concerning the heat transfer coeffi-
cient ('HTC') are divided into the groups constant heat transfer coefficient, time dependent heat
transfer coefficient and temperature dependent heat transfer coefficient. The grouping depends
on the selected dataset. In the field 'Groups' the group(s) related to the selected data is shown.

Use the function 'Group Filter' to select data of a special group. Only those datasets matching to
your selection will be shown in the list in the left part of the main window. In case of the heat trans-
fer coefficients you can e.g. choose the group filter 'Constant' if you want to display constant heat
transfer coefficients only. The default for 'Group Filter' is 'All': All datasets of the selected type are
shown.

! If you create a new dataset ('New'), please note that this dataset is automatically mem-
ber of the group currently selected under 'Group Filter'. If the 'All' entry is activated there,
MAGMASOFT® chooses the first available group.

'Short Description' shows additional information and notes about the selected data. Typical in-
formation that you can place here are specifications, a confidential company label or how the data
are to be used.

'Status' shows the status of the selected dataset. 'Ready to use' means that this dataset is of ad-
equate quality for simulation needs.

! Please note that you must activate 'Ready to use' in order to make the data available
within the program.
CH. 8: DATABASES 8-11

'Protection' indicates if the dataset is protected by a password or by a license key. If the dataset
is protected, it cannot be viewed or edited.

! Please refer to the Ch. "Assign Information to a Dataset / 'Global Information'", page
8-13 pp, for further information on these functions.

8.1.3 General Database Functions

View Data / 'View'

Proceed as follows to view data of a database:

Ö Start MAGMAdata.

Ö Open the 'Database' menu and select the database you want to work with.

Ö Open the 'Dataset' menu and select the type of data you want to look at.

Ö In the list on the left select the name of the dataset you want to look at.

Ö Choose 'View' from the menu field to look at the selected dataset.

Depending on the selected dataset there are different windows available. See the information con-
cerning the corresponding data in Ch. 8.2, page 8-25 to Ch. 8.7, page 8-97.

Create New Data / 'New'

Use this function to create a completely new dataset. Proceed as follows:

Ö Start MAGMAdata.

Ö Open the 'Database' menu and select the database you wish to create the dataset in. Note
that the database 'MAGMA' cannot be modified and is therefore not ready to receive new
datasets.

Ö Open the 'Dataset' menu and select the type of data to which you want to add a new dataset.

Ö If there are groups within the selected type of data, mark the corresponding group in the
'Group Filter' with the left mouse button. If no group is selected, the first entry of the 'Groups'
list is taken as default group.

Ö Choose 'New' from the menu field to enter a new dataset.

Ö Enter the name of the new dataset.

8-12 MAGMASOFT® 4.4 MANUAL

Depending on the selected type of data (which corresponds to the entry chosen under 'Dataset')
there are different windows available. See the information concerning the corresponding data in
Ch. 8.2, page 8-25 to Ch. 8.7, page 8-97.

Modify Data / 'Edit'

Proceed as follows to change existing data:

Ö Start MAGMAdata.

Ö Open the 'Database' menu and select the database you want to work with. Note that the da-
tabase 'MAGMA' cannot be modified.

Ö Open the 'Dataset' menu and select the type of data you want to modify.

Ö In the list on the left select the name of the dataset you want to modify.

Ö Choose 'Edit' from the menu field. Choose again 'Edit' from the window that appears now, as
well as one of its entries, in order to modify data (Fig. 8-2).

Ö Choose 'Save' from the 'Data' menu in order to store the modifications permanently.

Depending on the selected type of data there are different windows for editing the information. See
the information concerning the corresponding data in Ch. 8.2, page 8-25 to Ch. 8.7, page 8-97.

Copy Data / 'Copy'

This function is useful if you want to create data that do not differ very much from an existing
dataset. First make a copy of the existing dataset. Proceed as follows to copy a dataset:

Ö Start MAGMAdata.

Ö Open the 'Database' menu and select the database where you want to copy a dataset. Note
that the database 'MAGMA' cannot be modified.

Ö Open the 'Dataset' menu and select the type of data you wish to create a new dataset for.

Ö In the list on the left select the name of the dataset you want to copy.

Ö Choose 'Copy' from the menu field to create a copy of the selected dataset.

Ö Enter the name for the new dataset.

Then you can modify the new dataset with the 'Edit' function.
CH. 8: DATABASES 8-13

Delete Data / 'Delete'

Ö Start MAGMAdata.

Ö Open the 'Database' menu and select the database you want to work with. Note that the da-
tabase 'MAGMA' cannot be modified.

Ö Open the 'Dataset' menu and select the data type, of which you want to delete data.

Ö In the list on the left select the name of the dataset you want to delete.

Ö Choose 'Delete' from the menu field to delete the selected dataset.

Delete All Data / 'Delete All'

Ö Start MAGMAdata.

Ö Open the 'Database' menu and select the database from which you want to delete all datasets
of a type. Note that the database 'MAGMA' cannot be modified.

Ö Open the 'Dataset' menu and select the data type.

Ö Choose 'Delete All' from the menu field to delete all data of the selected type.

Assign Information to a Dataset / 'Global Information'

Each dataset contains global information describing the origin and the use of the corresponding
data. The corresponding window is called 'Global Information' (Fig. 8-2). It appears for each
dataset when you activate the 'View' or 'Edit' button in the main window (Î Fig. 8-1, page 8-8). If
you choose 'View', all editing functions within 'Global Information' are deactivated. In this case you
can view all information, but not edit them.
8-14 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
Select data type
Select dataset
Edit
'Edit' menu
'Global Information'

Fig. 8-2: Assigning information to data

'Re-Load'

You can restore the original state of a dataset that has been changed, but not saved, as follows:

Ö Open the 'Data' menu and choose the function 'Re-Load'.

Ö Changes that have not been stored with 'Save' are not saved.

'Load Backup'

Data that existed before executing the last 'Save' command are kept as a backup copy and can
be recovered if wanted. Proceed as follows:

Ö Open the 'Data' menu and choose the function 'Load Backup'.

Ö All recent changes are lost now.

This function is available in the 'Edit' mode only.

CH. 8: DATABASES 8-15

'Save'

You can save changes that you performed at a dataset as follows:

Ö Open the 'Data' menu and choose 'Save'.

Ö All changes are saved.

This function is available in the 'Edit' mode only.

'Import Picture'

You can assign a picture (GIF format) to each dataset. Proceed as follows:

Ö Select the entry 'Picture' from the menu 'Data', then choose 'Import Picture'. A window for the
selection of the picture appears. In case the directory of the current project version contains
pictures in the GIF format, these appear under 'Choice'. If the wanted picture is stored in a
different directory, select 'Other'. Two new options appear in the window, 'Directory' and 'Se-
lect'.

Ö Choose the directory that contains the wanted picture via the input field under 'Directory' or
the 'Select' button. (In the latter case, a new window appears that helps you to search for the
directory. There, confirm with 'OK' once you have found the correct directory).

Ö All GIF files of the selected directory appear under 'Choice'. Choose the wanted picture there.
It then appears under 'Selected', too.

Ö Choose 'Import'. The picture is copied and assigned to the dataset. The window closes, and
the picture is inserted into the 'Global Information' window, above 'Short Description'.

If you want to remove a picture from a dataset, select the entry 'Picture' from the menu 'Data' and
then the 'Delete Picture' function. The picture is deleted, that is, it is removed from the dataset and
does no longer appear under 'Global Information'.

This function is available in the 'Edit' mode only.

'Close'

Use 'Close' in order to close the window and to return to the main window. If you made changes
that are not stored, a security message window appears. Proceed as follows:

Ö Choose 'Close' in the 'Data' menu.

Ö Choose 'Yes' in the following message window if you want to save changes.
8-16 MAGMASOFT® 4.4 MANUAL

Ö Choose 'No' if you do not want to save changes.

Ö Choose 'Cancel' if you want to abort the closing of the window. It then stays open.

'Edit'

The entries of the 'Edit' menu in the menu bar depend on the selected type of data ('Dataset' menu
in the main window) as well as on the selected group ('Groups'). Within the subentries of this menu
you can make the actual data definitions and modifications, provided you have previously chosen
'Edit' in the main window. After you have chosen 'Edit' or 'View', the 'Global Information' window
always appears (default). This window then changes according to the entry chosen under 'Edit'
(see picture above). Please refer to Ch. 8.2, page 8-25 to Ch. 8.7, page 8-97 for details on these
entries.

'Short Description'

Enter a short description of the dataset, e.g. internal or company specific material names.

'Groups'

Select (if existing) the groups from the list to which the dataset shall belong. The grouping de-
pends on the previously selected dataset. The individual groups are described in Ch. 8.2, page
8-25 to Ch. 8.6, page 8-90.

'Status' / 'Ready to use'

Activate the button 'Ready to use' if you want to make the dataset available for use within MAG-
MASOFT®. Only those data that have been activated here are available in the program.
Make sure to activate 'Ready to use' only if the dataset is correct.

The following is valid for the 'Ready to use' function:

• All datasets of the 'MAGMA' database are activated.

• All new datasets created by you are deactivated. You must activate them before you can use
them in MAGMASOFT®.

• All copied datasets take over the status of the original dataset.

! Please note that you must activate 'Ready to use' in order to make the data avail-
able within the program.
CH. 8: DATABASES 8-17

'Protection'

If you want to protect data with a password, activate the 'Password-Protected' entry under 'Pro-
tection', enter a password containing at least 8 characters and confirm with 'OK'. Now your data
can be edited and viewed after entering the password only. The MAGMASOFT® modules, how-
ever, have still free access to the data. The default here is 'Unprotected'.

For changing the password, you have to be in the 'Edit' mode. Click again on 'Password-Protected'
and enter a new password. If you want to delete the password, click again on 'Unprotected' in the
'Edit' mode.

'Memo'

You can extend your dataset with detailed comments that contain e.g. the origin or explanation of
the properties of the data. You can enter and view the memo in a text window (Fig. 8-3).

database
'Database' menu
Select database
'Dataset' menu
Select data type
Select dataset
Edit
'Edit' menu
'Memo'

Fig. 8-3: Entering a memo

Ö Select the function 'Memo' from the menu bar to open the corresponding window.

Ö Enter the text of the memo.

8-18 MAGMASOFT® 4.4 MANUAL

Ö Quit the window with 'OK'.

Import Data from Databases / 'Import'

If you install a release of MAGMASOFT® for the first time, only the database 'MAGMA' is filled with
data. It is not necessary to enter all datasets once again to work in other databases, e.g. 'Global'.
MAGMASOFT® provides the possibility to exchange data between databases. If you have chosen
the desired database and dataset, you can read datasets from another database. Please proceed
as follows if you want to copy data from one database into another:

Ö Open the 'Database' menu from the main window and select the database in which you want
to import data (target database).

Ö Open the 'Dataset' menu from the main window and select the type of data of which you want
to import data. In case you want to import datasets of two or more types (e.g. materials and
heat transfer coefficients), you have to perform the import for each type individually.

Ö Open the 'Import' menu from the main window and select the database from which you want
to import data (source database, Fig. 8-4).

database
'Database' menu
Select target data-base
'Dataset' menu
Select data type
'Import' menu
Select source database

Fig. 8-4: Importing datasets into a different database

CH. 8: DATABASES 8-19

On the left of the window you find a list with the datasets of the source database. The list on the
right shows those datasets that are to be imported into the target database. Proceed as follows:

Ö Select the datasets you want to import with the left mouse button. Use the buttons between
the lists to move the datasets. A doubleclick with the left mouse button on an element of a list
moves this dataset to the other list, too.

Ö Start the import using the 'Import' button. The selected dataset is added to the target data-
base. If there is an existing dataset with the same name as a dataset to be imported, a window
will ask you whether the existing dataset element should be overwritten.

Ö The 'Import' window closes.

Use the button 'Cancel' to leave the window without changes.

Import Data from a Different Project's Database / 'Import From Other Project'

It is also possible to exchange data between different projects. Proceed as follows:

Ö Open the 'Database' menu from the main window and select the database in which you want
to import data (target database).

Ö Open the 'Import' menu from the main window and select 'From Other Project'. The window
'Open Project' appears. This window is the same as the one belonging to the 'open project'
function of the project administration.

Ö Select a project version and the file "<project name>.db". Please refer to Ch. 2.3, page 2-6 of
this manual for details.

Ö Choose 'OK'. The 'Open Project' window closes, and the wanted project is selected.

Ö Please refer to the description of the 'Import' function for the further proceeding.

Import Data from Release 2 / 'Import From Release 2'

In order to import data from the MAGMASOFT® Release 2 database, you have to define where
these are located (in addition to the information mentioned above). Proceed as follows:

Ö Open the 'Database' entry in the main window and select the database, into which you want
to transfer the data (target database).

Ö In the main window, choose the entry 'Import From Release 2' (Fig. 8-5) from the 'Import'
menu.
8-20 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select target database
'Import' menu
'From Release-2'

Fig. 8-5: Importing data from Release 2

Ö Enter the path of the corresponding files in the field 'Library directory of MAGMASOFT Re-
lease-2'. (Normally the databases of Release 2 are stored in a path like ".../inst2/v2.x.x/lib".)
You may also use the button 'Select' to select the path. Thererupon the following window ap-
pears:
CH. 8: DATABASES 8-21

database
'Database' menu
Select target database
'Import' menu
'From Release-2'
'Select'

Fig. 8-6: Searching directory for data from Release 2

Ö Change to the directory in which the desired file is stored via mouse click in the list. With [..]
you change to the next higher directory. (Directories are shown in square brackets in the list.)

If you choose 'Directories', you can change to your home directory ('Home', only on UNIX), to
the directory of the current project version ('Current Project') or, via a selection window, to a
directory of your choice ('Other Projects'; please refer also to the description of 'Import From
Other Project' on page 8-19).

The chosen directory is shown above the list next to 'Directory'.

Ö Leave the window with 'OK' to return to the window 'Import From Release 2'.

Ö Select either 'MAGMA' or 'USER' as source database there.

8-22 MAGMASOFT® 4.4 MANUAL

Ö Select the datasets as described in the 'Import' chapter (Î page 8-18) and invoke the import
with 'Import'.

! The data of Release 3 are fully compatible to Release 4. There is no need to import
them. Please note, though, that you cannot use Release 4 data with MAGMASOFT® re-
lease 3.x.

Recreate Database Index / 'Recreate Index'

If you have copied data or files using your operating system (e.g. after having purchased new da-
ta), you should recreate the index of your database. If you do not recreate the index, MAGMA-
SOFT® will not be able to use the new data.

Ö Open the 'Utilities' menu and choose the function 'Recreate Index'.

Ö Now the index of the database is recreated. The new datasets now appear in the list of the
main window.

'Delete Backup Files'

MAGMASOFT® enables you to delete the backup files of the database that is currently active.

Ö Open the 'Utilities' menu and choose the function 'Delete Backup Files'. Confirm the following
security message with 'Yes'.

Ö Thereupon all backup files of the currently active database are deleted.

Database Archive / 'Pack/Unpack Database Archive'

You can pack a database into a file for transferring purposes, and you can also unpack this file
again.

Ö If you want to pack a database, use the 'Database' menu to select the database that you want
to pack into a file.

Ö Choose 'Utilities' Î 'Pack Database Archive'.

The selected database is now packed. After this is complete, a file called "<base directo-
ry>.tam" exists in the directory where the database is located. If you have e.g. packed the 'User'
database, the program creates a file "<home directory>/MAGMAsoft/UserDB.tam".

Ö If you want to unpack a packed database, first choose the database that you want to unpack
via the 'Database' menu.
CH. 8: DATABASES 8-23

Ö Choose 'Utilities' Î 'Unpack Database Archive'.

Ö Now the program scans the corresponding base directory for a file that corresponds to the de-
scribed naming conventions and restores the database contents that existed when the data-
base was packed.

! Caution! If you unpack a database, the original content of this database will be
lost!

Success or errors occuring during the packing and unpacking process are shown in a message
window.

A ".tam" file is a special MAGMASOFT® archive file, which can be processed only with the com-
mands described above. It is not possible to edit such a file with external programs (e.g. WinZip).

'Convert Project Files'

Normally MAGMASOFT® stores all project data in a binary format, ensuring a fast access. How-
ever, this file format is not exchangeable between all platforms. If you are working with multiple
workstations (e.g. in an user group), maybe you have to work on the same projects from different
platforms. This may lead to problems reading project files. MAGMASOFT® allows you to convert
project files of the current version of your project to another format.

The ASCII format is a text format that is compatible on all platforms, but the access is very slow
and needs a lot of memory. The binary format 'XDR' is a good compromise, because it is a stan-
dard compatible across all platforms and allows fast access. We recommend you to use the 'XDR'
format.

You can also use the 'Compressed' file format, which is an improvement of the binary format. In
this case the data are stored in a compressed form. This saves disk space.

If you want to convert project files into another format, proceed as follows:

Ö Make sure you have opened the project that is to be converted and the corresponding version
(menu 'project' Î function 'open project').

Ö Open the main database window, open the menu 'Utilities' and select the function 'Convert
Project Files'.

Ö At the top of the following window (Fig. 8-7), the project directory of the current version is
shown. On the left you find a list containing the project files of the version.
8-24 MAGMASOFT® 4.4 MANUAL

Ö Select the files to be converted from the 'Choice' list using the left mouse button. Use the but-
tons between the lists to exchange files between the 'Choice' and 'Selected' lists. Only the files
in the 'Selected' list will be considered for exchange.

Ö Select the target format for the conversion by activating one of the buttons 'ASCII', 'Binary',
'XDR' or 'Compressed'. We recommend the 'XDR' format, as it offers a good compromise be-
tween compatibility and convenient computing time.

database
'Database' menu
Select target database
'Import' menu
'Import from Release-2'

Fig. 8-7: Converting project files

Ö Start the conversion using the 'Convert' button. The files are converted into the selected for-
mat and are stored under the same names as before.

Use the button 'Cancel' to quit the window without performing a conversion.

Activate Windows / 'Windows'

If you have opened windows with the 'Edit' or 'View' buttons, they are also listed in the 'Windows'
menu and can be activated there. This function is convenient if you have opened several windows.
CH. 8: DATABASES 8-25

It enables you to change quickly between overlaying windows; you do not have to shift them with
the mouse.

8.2 Material Properties / 'Material'

Material data can be assigned to the following groups (multiple choices are possible):

• 'Cast Alloy'

• 'Core'

• 'Sand Mold'

• 'Insulation'

• 'Chill'

• 'Permanent Mold'

• 'Cooling'

• 'User Defined 1'

• 'User Defined 2'

Depending on the material group, the program needs more or less complex material properties
for simulation. Whereas the properties of the cast alloy have to be known in detail, less data are
needed for the sand mold, permanent mold etc. The recommended material data are explained
in the following chapters.

8.2.1 Melt / 'Cast Alloy'

The material group 'Cast Alloy' ('Material' Î 'Group Filter' Î 'Cast Alloy') is assigned to all vol-
umes of the casting system that contain melt. These volumes are assumed to be filled with air
when the simulation of mold filling starts. The melt flow into the mold is defined using the material
group 'Inlet' (which belongs to 'Cast Alloy' during simulation). The initial temperature at the begin-
ning of mold filling is T-initial. For solidification simulation either the temperature field from filling
simulation or T-initial is used as initial temperature.
8-26 MAGMASOFT® 4.4 MANUAL

The material properties of the cast alloy are most important for simulation. Depending on the sim-
ulation different material properties are needed. The more details you need to receive from simu-
lation results, the bigger are the demands on quality and range of the data needed for simulation.

'General Parameters'

You have to define the general material parameters in this window (Fig. 8-8):

database
'Database' menu
Select target database
'Import' menu
'Import from Release-2'

Fig. 8-8: Defining general material parameters

'Material type' This entry controls the available input fields for material data.
Each material belongs to a particular material type.
Available material types are:
• Iron
• Steel
• NF Copper
CH. 8: DATABASES 8-27

• NF Zinc
• NF Nickel
• NF Cobalt
• LM Aluminium
• LM Magnesium
• Sand
• Sleeve
• Other
NF ('Non-Ferrous') indicates that this alloy is non-ferrous, i.e. not
iron-based. It may, however, contain iron as an alloy element. LM
indicates that this alloy is a typical 'Light Metal' alloy.
The availability of the material parameters depends on the mate-
rial type as well as on your license / the MAGMASOFT® modules
that are presently active. Consult your module manuals if neces-
sary. The parameters described in the following are available for
standard MAGMASOFT®:
'Solidus temperature' At Tsol the whole melt is just solidified during the cooling process.
It is the lower limit of the Solid-Liquid interval.
'Liquidus temperature' At Tliq the very first part of the melt just starts to solidify during the
cooling process. It is the upper limit of the Solid-Liquid interval.
'Initial temperature' T-initial is the temperature that is taken as default initial temper-
ature of the cast alloy. If you make no other definitions during the
simulation setup, this temperature is used for cast alloy when
simulation starts. Please refer also to Ch. 5.2.1, page 5-8 of this
manual.
'Latent heat' The latent heat is the quantity of heat that is being absorbed or
emitted during a phase transition. It is called "latent" because the
absorption or emission of this heat does not lead to a temperature
change. This means that heat is absorbed from or transported
into the material without a temperature change.
In MAGMASOFT® 'Latent heat' describes the specific heat con-
tent of the cast alloy, which has to be absorbed from the liquid to
the solid state (melt heat). The unit is kilojoule per kilogram (stan-
dardized by mass).
8-28 MAGMASOFT® 4.4 MANUAL

(The heat of vaporization or condensation that is produced during

the liquid – gaseous phase transition is latent heat, too.)
'Solidification morphology' For calculation of feeding effects you can use two different mod-
els depending on the cast alloy:
• Default is 'short freezing range'. This model should be ade-
quate for use with short freezing range alloys, in particular for
pure metals, eutectic alloys, carbon steels, aluminum bronz-
es and S.G. (spheroidal graphite) cast iron.
• You should use the feeding model 'long freezing range' for
long freezing range or equiaxed solidifying alloys, which typ-
ically lead to more dispersed porosity formation. Examples
are hypereutectic and hypoeutectic alloys, as well as bronz-
es.
Note that the solidification morphology does not only depend on
the specific alloy but will also be influenced by the actual cooling
conditions during solidification.
Both feeding options will take the present cooling conditions into
consideration.
'Feeding effectivity' Percentage of solidified melt within a control volume, up to which
feeding in this cell is possible. No feeding is possible if the per-
centage of solidified melt exceeds this value. Please refer also to
page 5-52 of this manual.
'Rheology model' In standard MAGMASOFT®, the Newtonian rheological model is
available. Please refer to page 8-37 pp for details.

! If you select the 'Sand' material type, please note that the parameter 'Initial temperature'
is the only one available.

Ö Save new values using the 'Save' command from the 'Data' menu.

Thermal Conductivity / 'Lambda'

Thermal conductivity (Fig. 8-9) indicates the material's ability to transfer heat:

· ∆T
q = – λ ⋅ ------- Equation 8-1
∆x
CH. 8: DATABASES 8-29

·
q heat flow per surface [W/(m2)]

λ thermal conductivity [W/(mK)]

∆T
------- temperature gradient [K/m]
∆x

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'Lambda'

Fig. 8-9: Defining the thermal conductivity of a material

With the values on the left side you define thermal conductivity as a function of temperature. The
corresponding graph is shown on the right side. You can process the data as follows:
Select values: • Click on the desired graph point with the left mouse button or
• use the arrows keys to jump from point to point or
• mark the value pair in the list with the left mouse button.
8-30 MAGMASOFT® 4.4 MANUAL

If you want to select several value pairs, keep the left mouse button
pressed and move the cursor over the entries in the list.
Add new values: To add a new value pair to the list, enter the value pair in the field 'Input'.
You must separate the values by one or more blanks or by a tab stop.
Accept the value pair by pressing the return key.
Correct values: If the X value stays the same and if you just want to correct the Y value
of a value pair, then change the value in the field 'Input' according to
your wishes and confirm using the RETURN key.
If you want to change either the X value or both values of a value pair,
you have to delete the old value pair and to add the new one.
You can correct value pairs only individually.
Delete values: Select the desired values as described above.
Use the button 'Delete' to delete the selected value pair.
All values are deleted if you use the button 'Delete All'.
Import values: Choose 'Import'. The window 'Import from ASCII file' appears (Fig.
8-10).
CH. 8: DATABASES 8-31

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'Lambda'
'Import'

Fig. 8-10: Importing values from files

Ö Enter a search sequence (e.g. '*.*') into the field next to 'Filter' for
selecting the file.
Ö Change to the directory in which the desired file is stored via mouse
click in the list. With [..] you change to the next higher directory. (Di-
rectories are shown in square brackets in the list.)
If you choose 'Directories', you can change to your home directory
('Home', only on UNIX), to the directory of the current project ver-
sion ('Current Project') or, via a selection window, to a directory of
your choice ('Other Projects'; please refer also to the description of
'Import From Other Project' on page 8-19).
The chosen directory is shown above the list next to 'Directory'.
8-32 MAGMASOFT® 4.4 MANUAL

Ö Select the desired ASCII-file from the list. (Files are shown without
brackets.)
Ö Leave the window with 'OK' in order two return to the 'Lambda' win-
dow. The value pairs are copied into the database. Please note that
existing value pairs are overwritten without a safety prompt.

Density / 'Rho'

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'Rho'

Fig. 8-11: Defining the density of a material

The values on the left side define the density (mass per volume unit) as a function of temperature.
The corresponding graph is shown on the right side. The way to select, add, modify, delete or im-
port values is the same as explained in the overview on page 8-29. See this chapter for further
information.
CH. 8: DATABASES 8-33

Specific Heat Capacity / 'Cp'

The specific heat capacity is the amount of energy that is required to increase the material's tem-
perature by 1°C or that must be taken off in order to lower the material's temperature by 1°C. The
specific heat capacity refers to 1 kg of the respective material.

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'Cp'

Fig. 8-12: Defining the specific heat capacity of a material

The values on the left side define the specific heat capacity as a function of temperature. The cor-
responding graph is shown on the right side. The way to select, add, modify, delete or import val-
ues is the same as explained in the overview on page 8-29. See this chapter for further
information.
8-34 MAGMASOFT® 4.4 MANUAL

Fraction Solid / 'fs'

Between Tsol and Tliq the melt contains liquid as well as solid portions. Fraction solid fs is the ratio
of the solidified portion to the total amount of alloy (liquid and solid). At Tsol fs is always '1' and at
Tliq fs is always '0'. The development of fraction solid fs (T), on the other hand, depends on the
alloy.

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'fs'

Fig. 8-13: Defining the solidification interval of a material

The values on the left side define fs (T). The corresponding graph is shown on the right side. The
way to select, add, modify, delete or import values is the same as explained in the overview on
page 8-29. See this chapter for further information.

Remark for aluminum and steel alloys: The fraction liquid and fraction solid results for solidification
in the postprocessor (Î page 42 pp of the Postprocessor on Geometry 4.4 Manual) are based on
the curve that is calculated here.
CH. 8: DATABASES 8-35

Specific Heat Content / 'Rho*Cp (view only)'

The specific heat content (Rho*Cp) is the heat per volume, which is needed to increase the tem-
perature of a material by one degree. This value already includes the effect of latent heat for the
phase change between the solid and the liquid phase. The course of fraction solid between Tsol
and Tliq is considered for calculation. The consideration of latent heat leads the to curve's peak in
the area of the solidification interval. The program automatically performs the calculation. You can
view, but not edit the values.

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
'Edit'
'Edit' menu
'Rho*Cp'

Fig. 8-14: Display of the specific heat content of a material

The values on the left define the specific heat content. The corresponding graph is shown on the
right side.
8-36 MAGMASOFT® 4.4 MANUAL

'Flow Properties'

The 'freezing temperature' value defines the temperature limit, below which the flow is not possible
anymore due to solidified melt. You can define the freezing temperature using the following pres-
sure dependent equation:

2
TG ( p ) = K0 + K1 ⋅ p + K2 ⋅ p Equation 8-2

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
'Edit'
'Edit' menu
'Flow properties'

Fig. 8-15: Defining the flow properties of a material

If you make no entries, MAGMASOFT® calculates a default freezing temperature TG for the ma-
terial flow using the equation:

T G = T Sol + ( T Liq – T Sol ) ⋅ 0.25 = K 0 Equation 8-3

! Use the function 'Calculate Default Properties' to calculate the constant K0 as the freez-
ing temperature described above. In this case the other constants are taken to be 0 so
that TG is not pressure dependent.

The function 'Flow Properties' is not available for materials of the 'Sand' type.
CH. 8: DATABASES 8-37

Flow Properties – Newtonian Rheology Model / 'Rheology'

In standard MAGMASOFT®, the Newton rheology model is available. In the 'Newtonian Viscosity'
window (see below) you have to define the respective temperature dependent viscosity curve. In
MAGMASOFT® viscosity is assumed to be in correspondence to liquidus temperature (taken from
the defined viscosity curve) and kept constant:

ν = ν ( T Liquidus ) Equation 8-4

Exceptions are the material group 'Ingate' if you use the high pressure die casting module (MAG-
MAhpdc) and the MAGMAthixo module. Here viscosity is assumed to be temperature dependent.
The unit commonly used for dynamic viscosity is Pa ⋅ s.

The following functions are available:

• 'Newtonian-Parameters':

If you want to activate the curve that you defined under 'Newtonian Viscosity', choose the function
'Rheology' Î 'Newtonian-Parameters' Î 'Active': 'Yes'.

• 'Newtonian-Viscosity':

If you want to define viscosity as a function of temperature, choose 'Rheology' Î 'Newtonian-Vis-

cosity' (Fig. 8-16).

A fluid's dynamic viscosity is a measure for the flow's resistance against shear strain and is de-
fined as follows:

dv
τ = η ⋅ ------ Equation 8-5
dz

τ Shear strain [N/m2]

η Dynamic viscosity [Ns/m2]

dv
------ Velocity gradient [1/s]
dz
8-38 MAGMASOFT® 4.4 MANUAL

The higher the viscosity's value is, the more "viscuous" the fluid becomes. In MAGMASOFT® only
the kinematic viscosity is used, which results from the relation of dynamic viscosity to density:

ν = η
--- Equation 8-6
ρ

ν Kinematic viscosity [m2/s]

η Dynamic viscosity [Ns/m2]

ρ Density [kg/m3]

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'Rheology'
'Newtonian-Viscosity'

Fig. 8-16: Defining the Newtonian viscosity of a material

CH. 8: DATABASES 8-39

The values on the left define the kinematic viscosity as a function of temperature. The correspond-
ing graph is shown on the right side. The way to select, add, modify, delete or import values is the
same as explained in the overview on page 8-29. See this chapter for further information.

! In case a MAGMAthixo license is active, there are several other rheology models avail-
able. Please refer to the MAGMAthixo 4.4 Manual for details.

The function 'Rheology' is not available for materials of the 'Sand' type.

'Erosion Properties'

You can define the parameters required for the calculation of mold erosion under 'Erosion Prop-
erties' (Fig. 8-17). You can activate the calculation of the erosion criteria during the simulation set-
up ('calculate erosion', Î page 5-29 of this manual). This function enables you to predict mold
damaging caused by too high melt flow velocities.

You have to define the following parameters in the database in advance:

'Reference velocity' Enter a reference velocity in metres per second.
'Reference time' Enter a reference time in seconds.

Mold erosion is calculated if the metal flow will exceed the 'Reference velocity' for a time scale that
exceeds the critical period of time entered under 'Reference time'.

In the 'MAGMA' database, you are given these values for all material datasets of the groups 'Core',
'Sand-Mold' and 'Permanent Mold' (Î 'Group Filter'). If you model the geometry in the preproces-
sor, the two parameters are available for the material groups 'Sand-Mold', 'Permanent-Mold',
'Core', 'User1', 'User2' and 'Shell'.

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
'Erosion Properties'

Fig. 8-17: Defining the erosion parameters of a material

8-40 MAGMASOFT® 4.4 MANUAL

If you have considered the calculation of erosion during simulation, you can display the corre-
sponding results in the postprocessor. Please refer also to Ch. 4.4.2, page 59 of the Postproces-
sor on Geometry 4.4 Manual, where this function is explained in detail.

! If the values calculated during simulation are lower than 10% of the reference values
that you have specified here – that is if there is no danger of mold erosion – , the results
are not written on your hard disk.

'Material Composition'

You can individually specify the composition of the materials using this menu and its submenues.
The entry in the 'Edit' menu corresponds to the entry under 'Material type' (e.g. 'LM Aluminium
Composition' for 'LM Aluminium', 'Iron Composition' for 'Iron', etc.). The window that appears also
depends on the material type. Here you have to enter the alloy elements in %.

A typical average composition is provided in the respective standard datasets in the MAGMA da-
tabase.

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
Menu 'Edit'
'[Material] Composi-
tion'

Fig. 8-18: Defining material composition

Fig. 8-18 shows an example for the composition of a material of the 'LM Aluminium' type. The alloy
elements and their number depend on the material type.

! • For iron casting simulations with MAGMAiron, the composition of iron and sand ma-
terials is important (Î Ch. 3.2, page 20 pp of the MAGMAiron 4.4 Manual).
CH. 8: DATABASES 8-41

• For steel casting simulations with MAGMAsteel, the composition of steel materials
is important (Î Ch. 4.1.1, page 28 of the MAGMAsteel 4.4 Manual).

'Material Properties'

You can specify additional properties of the materials of the 'Steel', 'Sand' and 'Sleeve' type using
this menu and its submenus. Depending on your license (MAGMASOFT® modules currently ac-
tive) and the selected material this menu is active or not. Consult your module manuals if neces-
sary. The entry in the 'Edit' menu corresponds to the entry under 'Material type' ('Steel Properties'
for 'Steel', 'Sand Properties' for 'Sand' and 'Sleeve Properties' for 'Sleeve'.).

If you invoke the properties of exothermic feeders in standard MAGMASOFT®, 'Sleeve Proper-
ties' (material type 'Sleeve'), the submenues 'Exothermic Properties' and 'Permeability' appear. If
you choose 'Exothermic Properties', the window with the same name appears (Fig. 8-19). There
you have to define the exothermic properties. These are:
'Ignition Temperature' Enter the feeder's ignition temperature in °C.
'Burn Time' Enter the feeder's burn time in seconds.
'Heat Generation' Enter the thermal count that is generated by the exothermic reac-
tion in kilojoules.

database
'Database' menu
Select database
'Dataset' menu
'Material'
Select material
Edit
'Edit' menu
[Sleeve] Properties
Exothermic Properties

Fig. 8-19: Defining the exothermic properties of a material

! In case you choose the 'Sleeve' material type and do not define exothermic properties
here, an error message appears when the solidification simulation is invoked.
8-42 MAGMASOFT® 4.4 MANUAL

If you choose 'Permeability, a window appears where you have to define the permeability of the
exothermic feeder in cm3/min.

! Feeders that are not exothermic are normally assigned to the material type 'Other'.

Under 'Steel Properties' you define the following properties:

• 'Permeability' (of the mushy zone)

• 'Partition-Coefficient'

• Solutal 'Expansion-Coefficient'

• 'Solid-Diffusivity'

Please refer to the MAGMAsteel 4.4 Manual for details.

Under 'Sand Properties' you have to define the permeability of the sand material in cm3/min.

! The following list shows all materials ('Group Filter' Î 'All'). In Ch. 8.2.1, page 8-25 to
Ch. 8.2.9, page 8-48 the materials are listed again, specified for each group.

Material Datasets in the 'MAGMA' Database

Depending on your license agreement, the 'MAGMA' database contains some or all of the follow-
ing cast alloy material data:
AE42 AIR Air_VDI
Al2O3 AlCu4 AlSi05
AlSi10Mg AlSi12 AlSi12Cu
AlSi12Cu3Ni2Mg AlSi12CuNiMg AlSi17Cu3_P
AlSi6Cu4 AlSi7Mg AlSi7Mg06
AlSi9Cu3 AlZnMgCu1.5 AM50
AM60B AZ91 C19Mn5
Ck25 COLDBOX COOLMED
Copper CR_SAND CR_SAND_DRY
CuAl10Fe CuAl10Ni CuAl8Mn
CuAl9Ni CuCoBe CuSn12
CuSn5ZnPb CuZn30 CuZn38Pb
CH. 8: DATABASES 8-43

CuZn40 EXTBOUNDARY FURAN

GJL-150 GJL-200 GJL-250
GJL-300 GJL-350 GJS-400
GJS-500 GJS-600 GJS-700
GJV-450 Graphit GREEN_SAND
GS_C25 GS16Mn5 GS17CrMo5_5
GS17CrMoV5_11 GS18CrMo9_10 GS20Mn5
GS22CrNi3_14 GS24Mn4 GS25CrMo4
GS30Mn5 GS34CrMo4 GS38
GS52 GS80CrMo8_4 GX120Mn13
GX22CrMoV12_1 GX2CrNiMoCuWN25_8_4 GX3CrNiMoCuN26_6_3_3
GX40CrSi13 GX5CrNi13_4 GX5CrNiMoNb18_10
GX6CrNi18_9 HEATMED HS21
IN718 IN939 Insulation
NiCr28W Oil160 OL_SAND
PbSb1.8 RZ5 SHELL_SAND
SiC SILICA_DRY SiO2
Sleeve Sn STEEL
Water X15CrNiSi20_12 X20Cr13
X210Cr12 X2NiCrMoCu25_20_5 X38CrMoV5_1
X40CrMoV5_1 X40CrNiSi25_20 X40CrNiSi27_4
X40NiCrSi35_25 X5CrNi18_10 X70Cr29
ZAMAK5 ZR_SAND ZR_SAND_DRY
default.air

! The MAGMA database has been compiled from various reputable sources, which used
the latest scientific methods and knowledge, and is believed by MAGMA to contain the
best available data at time of publication. However, MAGMA gives no guarantee about
accuracy of the data and accepts no liability for the consequences of its use.
Please refer also to the respective information under 'General Parameters' Î 'Short De-
scription'.

Materials for Cast Alloys in the 'MAGMA' Database

AE42 AlCu4 AlSi05

8-44 MAGMASOFT® 4.4 MANUAL

AlSi10Mg AlSi12 AlSi12Cu

AlSi12Cu3Ni2Mg AlSi12CuNiMg AlSi17Cu3_P
AlSi6Cu4 AlSi7Mg AlSi7Mg06
AlSi9Cu3 AlZnMgCu1.5 AM50
AM60B AZ91 C19Mn5
Ck25 Copper CuAl10Fe
CuAl10Ni CuAl8Mn CuAl9Ni
CuSn12 CuSn5ZnPb CuZn30
CuZn38Pb CuZn40 GJL-150
GJL-200 GJL-250 GJL-300
GJL-350 GJS-400 GJS-500
GJS-600 GJS-700 GJV-450
GS16Mn5 GS_C25 GS17CrMo5_5
GS17CrMoV5_11 GS18CrMo9_10 GS20Mn5
GS22CrNi3_14 GS24Mn4 GS25CrMo4
GS30Mn5 GS34CrMo4 GS38
GS52 GS80CrMo8_4 GX120Mn13
GX22CrMoV12_1 GX2CrNiMoCuWN25_8_4 GX3CrNiMoCuN26_6_3_3
GX40CrSi13 GX5CrNi13_4 GX5CrNiMoNb18_10
GX6CrNi18_9 HS21 IN718
IN939 NiCr28W PbSb1.8
RZ5 Sn STEEL
X15CrNiSi20_12 X20Cr13 X210Cr12
X2NiCrMoCu25_20_5 X38CrMoV5_1 X40CrMoV5_1
X40CrNiSi25_20 X40CrNiSi27_4 X40NiCrSi35_25
X5CrNi18_10 X70Cr29 ZAMAK5

8.2.2 'Core'

You must use the material group 'Core' ('Material' Î 'Group Filter' Î 'Core') for all volumes used
as core. If more than one cycle is calculated, it is assumed that a new core is used in each cycle.
This means that the temperature of the core is reset to T-initial at the beginning of each cycle.
CH. 8: DATABASES 8-45

In volumes of the material group 'Core' heat conduction is calculated. So initial temperature, heat
conductivity, specific heat content and density are the material properties that you must define.

Materials for Cores in the 'MAGMA' Database

Depending on your license agreement the MAGMA database contains some or all of the following
material data for use as 'Core':

• COLDBOX

• CR_SAND

• FURAN

• ZR_SAND

! The MAGMA database has been compiled from various reputable sources, which used
the latest scientific methods and knowledge, and is believed by MAGMA to contain the
best available data at time of publication. However, MAGMA gives no guarantee about
accuracy of the data and accepts no liability for the consequences of its use.

8.2.3 'Sand-Mold'

You must use the material group 'Sand Mold' ('Material' Î 'Group Filter' Î 'Sand-Mold') for all
volumes of the mold in sand casting processes. Simulation of batch casting is not possible using
the material group 'Sand Mold'.

In volumes of the material group 'Sand Mold' heat conduction is calculated exclusively. So initial
temperature, heat conductivity, specific heat capacity and density are the material properties that
you must define.

Materials for Sand Molds in the 'MAGMA' Database

Depending on your license agreement the MAGMA database contains some or all of the following
material data for use as 'Sand Mold':

• Al2O3

• COLDBOX

• CR_SAND

• CR_SAND_DRY
8-46 MAGMASOFT® 4.4 MANUAL

• FURAN

• GREEN_SAND

• OL_SAND

• SHELL_SAND

• SILICA_DRY

• Si02

• ZR_SAND_DRY

! The MAGMA database has been compiled from various reputable sources, which used
the latest scientific methods and knowledge, and is believed by MAGMA to contain the
best available data at time of publication. However, MAGMA gives no guarantee about
accuracy of the data and accepts no liability for the consequences of its use.

8.2.4 'Insulation'

You must use the material group 'Insulation' ('Material' Î 'Group Filter' Î 'Insulation') for all vol-
umes serving for insulation within the casting system.

In volumes of the material group 'Insulation' heat conduction is calculated. So heat conductivity,
specific heat and density are the material properties that you must define.

The MAGMA database contains the following materials for use as 'Insulation':

• Graphit

• Insulation

• Sleeve

8.2.5 'Chill'

You must use the material group 'Chill' ('Material' Î 'Group Filter' Î 'Chill') for all volumes of the
casting system serving as chills. Chills cool the melt using the effect of the specific heat capacity.
This means that materials with high heat capacity are most suitable as chills.

In volumes of the material group 'Chill' heat conduction is calculated. So heat conductivity, specific
heat content and density are the material properties that you must define.
CH. 8: DATABASES 8-47

Depending on your license agreement the MAGMA database contains some or all of the following
material data for use as 'Chill':

• Graphit

• SiC

• STEEL

8.2.6 'Permanent-Mold'

You must use the material group 'Permanent Mold' ('Material' Î 'Group Filter' Î 'Permanent-
Mold') for all volumes of the casting systems that serve as molds in die casting. Whereas the ma-
terial group 'Sand Mold' only allows calculation of one-off casting, you can use 'Permanent Mold'
for calculation of multiple casting cycles.

As initial temperature you can use T-initial or the temperature field resulting from the previously
calculated cycle. The value of T-initial depends on the selected material (Î Ch. 5.2.1, page 5-8
of this manual). After separation of casting and mold MAGMASOFT® assumes that the volumes
of the material group 'Permanent mold' cool against their surroundings.

Depending on your license agreement the MAGMA database contains some or all of the following
material data for use as 'Permanent Mold':

• Copper

• CuCoBe

• STEEL

• X38CrMoV5_1

• X40CrMoV5_1

8.2.7 'Cooling'

You must use the material group 'Cooling' ('Material' Î 'Group Filter' Î 'Cooling') for modeling
cooling channels within a casting system. It is assumed that the temperature of these volumes
remains nearly constant and that the resistance to heat flow is very low. Therefore 'Cooling' is re-
alized using an "artificial" material ('COOLMED') with very high heat capacity and very high heat
conductivity. You can control the cooling effect by the temperature of 'COOLMED' and the heat
8-48 MAGMASOFT® 4.4 MANUAL

transfer coefficient between 'COOLMED' and its surrounding material. With some modules of
MAGMASOFT® you can control the cooling times with an additional control mechanism.

The temperature of the material group 'Cooling' depends on T-initial of the material 'COOLMED'.
You should use the mean temperature between the beginning and the outlet of the cooling chan-
nels.

! In the air and water datasets the corresponding physical quantities are stored. In case
you use water or air (or another material that is physically realistic) instead of
'COOLMED', the cooling channel is heated up to the temperature of the neighboring
mold (stagnant water or stagnant air e.g. is assumed to be in the channel). Please refer
also to Ch. 8.3.6, page 8-64.

The MAGMA database contains the following materials for use as material 'Cooling':

• AIR

• Air_VDI

• COOLMED

• HEATMED

• Oil160

• Water

• default.air

8.2.8 User-Defined Group 1 / 'User-Defined 1'

The material group 'User-Defined 1' is reserved for special user needs. Note that within volumes
of the 'User-Defined 1' material group simulation contains heat flow only.

8.2.9 User-Defined Group 2 / 'User-Defined 2'

The material group 'User defined 2' is reserved for special user needs. Note that within volumes
of the 'User-Defined 2' material group simulation contains heat flow only.

You can use volumes of the material group 'User-Defined 2' for special boundary conditions at the
feeder. Normally standard outer ambient cooling is assumed for feeders, if the feeder is outside
of the mold. If you wish to apply your own boundary conditions, you should define a volume of the
CH. 8: DATABASES 8-49

material group 'User-Defined 2' in the preprocessor above the feeder. The heat flow from the feed-
er to this material will be controlled by the heat transfer coefficient between the feeder's top sur-
face and the special material layer. To keep the outer temperature on top of the feeder constant,
we recommend a material providing high specific heat capacity and high thermal conductivity, e.g.
the material 'EXTBOUNDARY'.

8.3 Internal Heat Transfers / 'HTC'

The heat transfer coefficient (HTC) describes how and to what extent heat is transferred across
boundaries between adjacent material groups, as for example the casting-mold boundary. A high-
er heat transfer coefficient corresponds to a better heat transfer.

Internal heat transfers exist between the material groups within the casting system. These heat
transfers between neighboring material groups are divided into the following groups in the data-
base:

• Constant

• Temperature Dependent

• Time Dependent

• Coating (if a coating is used)

• Cooling Channel – Standard (if cooling channels are used)

8-50 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Select dataset
Edit
'Edit' menu
'Global information'

Fig. 8-20: Overview of internal heat transfer coefficients

Depending on your choice of the group, specific windows for defining the heat transfer coefficients
appear. These are described in the following chapters.

Pleaser refer also to Ch. 5.2.2, page 5-11 of this manual, where the use of heat transfer coeffi-
cients in the simulation setup is explained.

8.3.1 Internal HTC Datasets in the 'MAGMA' Database

In the following table, all datasets for internal heat transfers in the 'MAGMA' database are listed.
You also find a short explanation for every heat transfer coefficient regarding its purpose (kind of
coefficient, (casting) process and materials / material groups if necessary).
Air_Cooling temperature dependent heat transfer coefficient for air cooling
Al_Whirlbath constant heat transfer coefficient for a heat treatment in an Al2O3 whirl
bath
AlCu4-coat temperature dependent heat transfer coefficient between AlCu4 and an
insulating coating of medium thickness in die casting
AlCu4-core temperature dependent heat transfer coefficient between AlCu4 and
core in die casting
CH. 8: DATABASES 8-51

AlCu4-mold temperature dependent heat transfer coefficient between AlCu4 and die
in die casting
Al-Sand temperature dependent heat transfer coefficient between an aluminum
alloy and mold sand
AlSi10Mg-coat temperature dependent heat transfer coefficient between AlSi10Mg and
an insulating coating of medium thickness in die casting
AlSi10Mg-core temperature dependent heat transfer coefficient between AlSi10Mg and
core in die casting
AlSi10Mg-HPDC temperature dependent heat transfer coefficient between AlSi10Mg and
die in an high pressure die casting process
AlSi10Mg-mold temperature dependent heat transfer coefficient between AlSi10Mg and
die in die casting
AlSi12-coat temperature dependent heat transfer coefficient between AlSi12 and an
insulating coating of medium thickness in die casting
AlSi12-core temperature dependent heat transfer coefficient between AlSi12 and
core in die casting
AlSi12Cu3Ni2Mg-coat temperature dependent heat transfer coefficient between
AlSi12Cu3Ni2Mg and an insulating coating of medium thickness in die
casting
AlSi12Cu3Ni2Mg-core temperature dependent heat transfer coefficient between
AlSi12Cu3Ni2Mg and core in die casting
AlSi12Cu3Ni2Mg-mold temperature dependent heat transfer coefficient between
AlSi12Cu3Ni2Mg and die in die casting
AlSi12Cu-coat temperature dependent heat transfer coefficient between AlSi12Cu and
an insulating coating of medium thickness in die casting
AlSi12Cu-core temperature dependent heat transfer coefficient between AlSi12Cu and
core in die casting
AlSi12Cu-HPDC temperature dependent heat transfer coefficient between AlSi12Cu and
die in an high pressure die casting process
AlSi12Cu-mold temperature dependent heat transfer coefficient between AlSi12Cu and
die in die casting
AlSi12CuNiMg-coat temperature dependent heat transfer coefficient between
AlSi12CuNiMg and an insulating coating of medium thickness in die
casting
8-52 MAGMASOFT® 4.4 MANUAL

AlSi12CuNiMg-core temperature dependent heat transfer coefficient between

AlSi12CuNiMg and core in die casting
AlSi12CuNiMg-mold temperature dependent heat transfer coefficient between
AlSi12CuNiMg and die in die casting
AlSi12-HPDC temperature dependent heat transfer coefficient between AlSi12 and
die in an high pressure die casting process
AlSi12-mold temperature dependent heat transfer coefficient between AlSi12 and
die in die casting
AlSi17Cu3_P-coat temperature dependent heat transfer coefficient between AlSi17Cu3_P
and an insulating coating of medium thickness in die casting
AlSi17Cu3_P-core temperature dependent heat transfer coefficient between AlSi17Cu3_P
and core in die casting
AlSi17Cu3_P-mold temperature dependent heat transfer coefficient between AlSi17Cu3_P
and die in die casting
AlSi6Cu4-coat temperature dependent heat transfer coefficient between AlSi6Cu4 and
an insulating coating of medium thickness in die casting
AlSi6Cu4-core temperature dependent heat transfer coefficient between AlSi6Cu4 and
core in die casting
AlSi6Cu4-mold temperature dependent heat transfer coefficient between AlSi6Cu4 and
die in die casting
AlSi7Mg06-coat temperature dependent heat transfer coefficient between AlSi7Mg06
and an insulating coating of medium thickness in die casting
AlSi7Mg06-core temperature dependent heat transfer coefficient between AlSi7Mg06
and core in die casting
AlSi7Mg06-mold temperature dependent heat transfer coefficient between AlSi7Mg06
and die in die casting
AlSi7Mg-coat temperature dependent heat transfer coefficient between AlSi7Mg and
an insulating coating of medium thickness in die casting
AlSi7Mg-core temperature dependent heat transfer coefficient between AlSi7Mg and
core in die casting
AlSi7Mg-HPDC temperature dependent heat transfer coefficient between AlSi7Mg and
die in an high pressure die casting process
AlSi7Mg-mold temperature dependent heat transfer coefficient between AlSi7Mg and
die in die casting
CH. 8: DATABASES 8-53

AlSi9Cu3-coat temperature dependent heat transfer coefficient between AlSi9Cu3 and

an insulating coating of medium thickness in die casting
AlSi9Cu3-core temperature dependent heat transfer coefficient between AlSi9Cu3 and
core in die casting
AlSi9Cu3-HPDC temperature dependent heat transfer coefficient between AlSi9Cu3 and
die in an high pressure die casting process
AlSi9Cu3-mold temperature dependent heat transfer coefficient between AlSi9Cu3 and
die in die casting
AlZnMgCu1.5-coat temperature dependent heat transfer coefficient between AlZnMgCu1.5
and an insulating coating of medium thickness in die casting
AlZnMgCu1.5-core temperature dependent heat transfer coefficient between AlZnMgCu1.5
and core in die casting
AlZnMgCu1.5-mold temperature dependent heat transfer coefficient between AlZnMgCu1.5
and die in die casting
AM50-HPDC temperature dependent heat transfer coefficient between AM50 (mag-
nesium alloy) and die in die casting
AM60B-HPDC temperature dependent heat transfer coefficient between AM60B and
die in an high pressure die casting process
AS-Saltbath constant heat transfer coefficient for a heat treatment in a salt bath
Aust_bath1 constant heat transfer coefficient for an austenitization process in a salt-
bath at a temperature of 1050°C
Aust_bath2 constant heat transfer coefficient for an austenitization process in a salt-
bath at a temperature of 1200°C
AZ91-HPDC temperature dependent heat transfer coefficient between AZ91 and die
in an high pressure die casting process
C0.001 constant heat transfer coefficient 0.001 W/m2K
C10.0 constant heat transfer coefficient 10 W/m2K
C100.0 constant heat transfer coefficient 100 W/m2K
C1000.0 constant heat transfer coefficient 1000 W/m2K
C10000.0 constant heat transfer coefficient 10000 W/m2K
C1500.0 constant heat transfer coefficient 1500 W/m2K
C200.0 constant heat transfer coefficient 200 W/m2K
C2000.0 constant heat transfer coefficient 2000 W/m2K
8-54 MAGMASOFT® 4.4 MANUAL

C300.0 constant heat transfer coefficient 300 W/m2K

C3500.0 constant heat transfer coefficient 3500 W/m2K
C400.0 constant heat transfer coefficient 400 W/m2K
C500.0 constant heat transfer coefficient 500 W/m2K
C600.0 constant heat transfer coefficient 600 W/m2K
C700.0 constant heat transfer coefficient 700 W/m2K
C7000.0 constant heat transfer coefficient 7000 W/m2K
C800.0 constant heat transfer coefficient 800 W/m2K
C900.0 constant heat transfer coefficient 900 W/m2K
Convection1 calculated temperature dependent heat transfer coefficient for a heating
process if convection occurs
Convection2 measured temperature dependent heat transfer coefficient for a heating
process if convection occurs
CStd temperature dependent heat transfer coefficient for an external bound-
ary (between casting system and its environment)
Gas1 constant heat transfer coefficient for a cooling in a vacuum oven (with
nitrogen convection 1 bar)
Gas2 temperature dependent heat transfer coefficient for a cooling in a vacu-
um oven (with nitrogen convection 5 bar)
Gas3 constant heat transfer coefficient for a cooling in a vacuum oven (with
nitrogen convection 3 bar)
Gas4 temperature dependent heat transfer coefficient for a forced convection
cooling (with nitrogen convection 10 bar)
Gas5 constant heat transfer coefficient for a cooling in a vacuum oven (helium
20 bar)
HA_steel-coat temperature dependent heat transfer coefficient between a high-alloyed
steel and an insulating coating of medium thickness in die casting
HA_steel-core temperature dependent heat transfer coefficient between a high-alloyed
steel and core in die casting
HA_steel-mold temperature dependent heat transfer coefficient between a high-alloyed
steel and die in die casting
INSU time dependent heat transfer coefficient for a good insulation
CH. 8: DATABASES 8-55

ISOFEEDER temperature dependent heat transfer coefficient for a completely insu-

lated feeder
LA_steel-coat temperature dependent heat transfer coefficient between a low-alloy
steel and an insulating coating of medium thickness in die casting
LA_steel-core temperature dependent heat transfer coefficient between a low-alloy
steel and core in die casting
LA_steel-mold temperature dependent heat transfer coefficient between a low-alloy
steel and die in die casting
MERGEMATERIALS constant heat transfer coefficient within one geometry (mold) with two
different MAT IDs (e.g. 6/1 and 6/2)
Oil1 temperature dependent heat transfer coefficient for the cooling in
Durixol4 oil at a temperature of 25°C without circulation
Oil2 temperature dependent heat transfer coefficient for the cooling in
Durixol4 oil at a temperature of 50°C with a circulation of 0.6 m/s
Oil3 temperature dependent heat transfer coefficient for the cooling in
Durixol_A650 oil at a temperature of 25°C without circulation
Oil4 temperature dependent heat transfer coefficient for the cooling in
Durixol_A650 oil at a temperature of 25°C with a circulation of 0.6 m/s
Oil5 temperature dependent heat transfer coefficient for the cooling in
Durixol_W25 oil at a temperature of 25°C without circulation
Oil6 temperature dependent heat transfer coefficient for the cooling in
Durixol_W25 oil at a temperature of 25°C with a circulation of 0.6 m/s
Oil7 temperature dependent heat transfer coefficient for the cooling in
Durixol_W27 oil at a temperature of 25°C with a circulation of 0.6 m/s
OPENFEEDER temperature dependent heat transfer coefficient for a feeder that is not
insulated
Oven1 constant heat transfer coefficient for a heating process in a furnace and
occurrence of convection
Oven2 constant heat transfer coefficient for a heating process in a furnace with
air movement
Saltbath1 constant heat transfer coefficient for the first heating process to 650°C
at a heat treatment in a salt bath
Saltbath2 constant heat transfer coefficient for the second heating process to
850°C at a heat treatment in a salt bath
8-56 MAGMASOFT® 4.4 MANUAL

Saltbath3 constant heat transfer coefficient for tempering in a salt bath at 550°C
Saltwater constant heat transfer coefficient for quenching in salt water
Steel-Sand temperature dependent heat transfer coefficient between steel and fu-
ran sand
TempIron temperature dependent heat transfer coefficient between cast iron and
mold sand
ZAMAK-HPDC temperature dependent heat transfer coefficient between ZAMAK and
die in an high pressure die casting process
cool-chann-oil cooling channel heat transfer coefficient for a cooling channel fed by oil
cool-chann-water cooling channel heat transfer coefficient for a cooling channel fed by
water
default.air constant heat transfer coefficient between air and cast alloy in spin cast-
ing
Please refer also to the respective information under 'General Parameters' Î 'Short Description'.

8.3.2 Constant Heat Transfer / 'Constant'

Datasets in the 'MAGMA' Database

The 'MAGMA' database contains the following datasets of constant heat transfer coefficients:
Al_Whirlbath AS-Saltbath Aust_bath1
Aust_bath2 C0.001 C10.0
C100.0 C1000.0 C10000.0
C1500.0 C200.0 C2000.0
C300.0 C3500.0 C400.0
C500.0 C600.0 C700.0
C7000.0 C800.0 C900.0
Gas1 Gas3 Gas5
MERGEMATERIALS Oven1 Oven2
Saltbath1 Saltbath2 Saltbath3
Saltwater default.air

Please refer also to the respective information given in the list in Ch. 8.3.1, page 8-50.
CH. 8: DATABASES 8-57

The group 'Constant HTC' contains constant heat transfer coefficients only, which are dependent
neither on temperature nor on time. The name of the heat transfer coefficient indicates the stored
value (C2000.0 means constant heat transfer with 2000 W/(m2K)).
W/(m2K) Watt per square meter and Kelvin

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group: Constant
Select dataset
Edit
'Edit' menu
'Constant HTC'
Fig. 8-21: Defining a constant heat transfer coefficient

8.3.3 Temperature Dependent Heat Transfer / 'Temperature Dependent'

Datasets in the 'MAGMA' Database

The 'MAGMA' database contains the following datasets of temperature dependent heat transfer
coefficients:
Air_Cooling AlCu4-coat AlCu4-core
AlCu4-mold Al-Sand AlSi10Mg-coat
AlSi10Mg-core AlSi10Mg-HPDC AlSi10Mg-mold
AlSi12-coat AlSi12-core AlSi12Cu3Ni2Mg-c
AlSi12Cu3Ni2Mg-core AlSi12Cu3Ni2Mg-perm AlSi12Cu-coat
AlSi12Cu-core AlSi12Cu-HPDC AlSi12Cu-mold
AlSi12CuNiMg-coa AlSi12CuNiMg-core AlSi12CuNiMg-mo
AlSi12-HPDC AlSi12-mold AlSi17Cu3_P-coat
AlSi17Cu3_P-core AlSi17Cu3_P-mol AlSi6Cu4-coat
AlSi6Cu4-core AlSi6Cu4-mold AlSi7Mg06-coat
AlSi7Mg06-core AlSi7Mg06-mold AlSi7Mg-coat
8-58 MAGMASOFT® 4.4 MANUAL

AlSi7Mg-core AlSi7Mg-HPDC AlSi7Mg-mold

AlSi9Cu3-coat AlSi9Cu3-core AlSi9Cu3-HPDC
AlSi9Cu3-mold AlZnMgCu1.5-coat AlZnMgCu1.5-core
AlZnMgCu1.5-mol AM50-HPDC AM60B-HPDC
AZ91-HPDC Convection1 Convection2
CStd Gas2 Gas4
HA_steel-coat HA_steel-core HA_steel-mold
ISOFEEDER LA_steel-coat LA_steel-core
LA_steel-mold Oil1 Oil2
Oil3 Oil4 Oil5
Oil6 Oil7 OPENFEEDER
Steel-Sand TempIron ZAMAK-HPDC
Please refer also to the respective information given in the list in Ch. 8.3.1, page 8-50.

Temperature dependent heat transfer coefficients serve to describe heat transfers that change
depending on temperature. Normally the heat transfer between two materials increases with in-
creasing temperature. Fig. 8-22 shows a corresponding draft. Solidification leads to contraction of
the volume. A gap appears between casting and mold. This means that the heat transfer coeffi-
cient at Tsol is lower than at Tliq.
CH. 8: DATABASES 8-59

Fig. 8-22: Increasing heat transfer coefficient with rising temperature

8-60 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group 'Temperature
Dependent'
Select HTC
Edit
Menu 'Edit'
'Temperature Depen-
dent HTC'

Fig. 8-23: Defining temperature dependent heat transfer coefficients

The values on the left define the heat transfer as a function of temperature. The corresponding
graph is shown on the right side. The way to select, add, modify, delete or import values is the
same as explained in the overview on page 8-29. See this chapter for further information.

8.3.4 Time Dependent Heat Transfer / 'Time Dependent'

In the 'MAGMA' database there is one dataset for a time dependent heat transfer coefficient ('IN-
SU').

Time dependent heat transfer coefficients define the heat transfer as a function of time. This de-
pendence on time can be caused by gaps between two materials, which can be reduced or en-
larged with time passing by.
CH. 8: DATABASES 8-61

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group 'Time depen-
dent'
Select dataset
Edit
'Edit' menu
'Time dependent HTC'

Fig. 8-24: Defining time dependent heat transfer coefficients

The values on the left define the heat transfer as a function of time. The corresponding graph is
shown on the right side. The way to select, add, modify, delete or import values is the same as
explained in the overview on page 8-29. See this chapter for further information.

8.3.5 Coating Heat Transfer / 'Coating'

The heat transfer coefficient of the type 'Coating' takes into account the additional thermal resis-
tance due to the coating of the mold. This additional resistance is defined by the coating's thick-
ness (Fig. 8-25) as well as by its thermal conductivity.
8-62 MAGMASOFT® 4.4 MANUAL

Thickness / 'Coating Defaults'

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group 'Coating'
Select dataset
Edit
'Edit' menu
'Coating Defaults'
Fig. 8-25: Defining the coating thickness

'Thickness' Thickness of the coating

You can use the following values for orientation:
Coating Thickness [mm]
Light 0.08
Medium 0.13
Thick 0.24

(If a license for the MAGMAlostfoam module is active, an additional field called 'Gas Permeability'
appears below 'Thickness'. There you must specify the coating's gas permeability. This, however,
is relevant for MAGMAlostfoam only (please refer to the corresponding manual for details).
Hence, if such a license is active, but you use another module or Standard MAGMASOFT®, you
can ignore this additional field.)

Thermal Conductivity / 'Lambda'

In the 'Edit' menu choose 'Lambda' to define the thermal conductivity of the coating. The way to
select, add, modify, delete or import values in this window is the same as explained in the over-
view on page 8-29. Here you can also activate the function 'Import Material Properties', which en-
ables you to import the thermal conductivity from the material database (Fig. 8-26).
CH. 8: DATABASES 8-63

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group 'Coating'
Select dataset
Edit
'Edit' menu
'Import Material Properties'

Fig. 8-26: Importing material properties for coat-

ings

Ö First select the database from which you want import material properties ('Database').

Ö Select the group of materials with 'Group Filter'.

Ö From the list, select the material whose properties you want to import. For ceramic coatings
you can e.g. choose the Al2O3 dataset from the 'Sand-Mold' group (as in Fig. 8-26), for coat-
ings with graphite you can e.g. choose the Graphit dataset from the 'Insulation' group.

Ö Confirm with 'OK'. The selected material properties are taken over and appear now in the win-
dow of 'Lambda' (thermal conductivity).
8-64 MAGMASOFT® 4.4 MANUAL

The heat transfer coefficient is calculated as follows, considering thickness and thermal conduc-
tivity of the coating:

λ
α = -----c Equation 8-7
dc

α Resulting heat transfer coefficient

dc Thickness of the coating

λc Thermal conductivity of the coating

! Effects caused by surface roughness and radiation, which occur in the technical pro-
cess, are not considered. The calculated heat transfer coefficient is only valid for an op-
timal contact between the coating and the die / casting.

Effective HTC / 'Effective HTC (view only)'

If you choose 'Effective HTC (view only)' from the 'Edit' menu, the heat transfer coefficient is cal-
culated based on the values for the coating's thickness and the thermal conductivity. It will be
shown in a separate window, which serves for controling the edited heat transfer. You can thus
only view these values, but not edit them.

The calculation is possible only if you have defined all values. This function is only active if this is
the case accordingly.

8.3.6 Cooling Channel Heat Transfer / 'Cooling Channel – Standard'

The 'MAGMA' database contains the following datasets of heat transfer coefficients for cooling
channels:

• cool-chann-oil

• cool-chann-water
CH. 8: DATABASES 8-65

'Cooling Channel Defaults'

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group 'Cooling Chan-
nel – Standard'
Select dataset
Edit
'Edit' menu
'Cooling Channel -
Standard'

Fig. 8-27: Defining the parameters for cooling channel heat transfers

In the 'Cooling Channel Defaults' window (Fig. 8-27), you have to define the following:
'Diameter' Hydraulic diameter of the cooling channel
'Length' Length of the cooling channel
'Flux' Flux of cooling material through the cooling channel
'Temperature' Medium temperature of the cooling material between entrance and out-
let of the cooling channel:

T inlet + T outlet
T = -------------------------------
- Equation 8-8
2

Further Properties of the Cooling Fluid

In the 'Edit' menu choose 'Lambda' (thermal conductivity), 'Rho' (Density), 'Cp' (specific heat ca-
pacity) and 'Viscosity' to assign the material properties of the cooling fluid. The way to select, add,
modify, delete or import values in these windows is the same as explained in the overview on page
8-66 MAGMASOFT® 4.4 MANUAL

8-29. You may also import these properties from the material database using the function 'Import
Material Properties' (Fig. 8-28).

database
'Database' menu
Select database
'Dataset' menu
'HTC'
Group 'Cooling Channel – Standard'
Select dataset
Edit
'Edit' menu
'Import Material Properties'

Fig. 8-28: Importing material properties for cool-

ing channels

Ö First select the database from which you want import material properties ('Database').

Ö Select the group of materials under 'Group Filter'. Normally you select 'Cooling' here.

Ö From the list, select the material whose properties you want to import.
CH. 8: DATABASES 8-67

Ö Confirm with 'OK'. The selected material properties are taken and appear now in the windows
of the functions mentioned above.

! You should select water, air or another physically realistic material as the basic material
for the calculation of the heat transfer coefficient. You should not consider 'COOLMED',
as the resulting heat transfer coefficient is not realistic (too high). Please refer also to
Ch. 8.2.7, page 8-47. It is a general prerequisite to know the exact flow rates.
You can also use oil tempering. The material dataset 'Oil160' is e.g. suited to calculate
the heat transfer coefficient with 'Cooling Channel Standard'.

The resulting heat transfer coefficient between the cooling medium and the wall of the cooling
channel is calculated from:

⋅ λ-
α = Nu
-------------- Equation 8-9
dh

Nu Nusselt number = F(Re, Geometry)

λ Heat conductivity of the fluid

dh Hydraulic diameter of the cooling channel

Effective HTC / 'Effective HTC (view only)'

If you choose 'Effective HTC (view only)' from the 'Edit' menu, the cooling channel HTC is calcu-
lated based on the values described above. It will be shown in a separate window, which serves
for controling the edited heat transfer. You can thus only view these values, but not edit them.

The calculation is possible only if you have defined all values. This function is only active if this is
the case accordingly.

8.4 External Boundaries / 'Boundary'

The data of this group describe the heat transfer between the casting system (mold, cast, feeders
etc.) and its surroundings, whereas in Ch. 8.3, page 8-49 the internal heat transfer between the
individual material groups is described only.
8-68 MAGMASOFT® 4.4 MANUAL

To consider radiation and convection effects, you can define the radiation coefficient ε and the
heat transfer coefficient α that is determined by convection as a function of temperature. MAG-
MASOFT® will then automatically calculate the effective heat transfer coefficient in combination
with the environment temperature. This temperature can differ depending on the process.

To consider the effects of convection, simply a temperature dependent heat transfer coefficient is
used.

! The datasets in the 'MAGMA' database (see following list) are being used auto-
matically. Normally you as the user must not change anything. Please do not
change the datasets of the 'Boundary' type. The available data has been verified,
and changes may lead to unrealistic results.

8.4.1 External Boundary Datasets in the 'MAGMA' Database

In the following table, all datasets for external boundaries in the 'MAGMA' database are listed. You
also find a short explanation for every external boundary regarding its purpose (kind of coefficient,
(casting) process and materials / material groups if necessary).
default standard boundary condition for the heat transfer between casting sys-
tem and its environment, considers radiation and convection
default.12 boundary condition for the material group 12 ('Feeder'), considers radi-
ation and convection
default.blow boundary condition for blowing of the die (temperature dependent heat
transfer coefficient)
default.coat boundary condition for the coating process (temperature dependent
heat transfer coefficient)
default.cool boundary condition for cooling channels in high pressure die casting
and LPDC (temperature dependent heat transfer coefficient)
default.dc boundary condition for die closing, considers radiation and convection
default.discas boundary condition for the casting after shake out in the DISAMATIC®
process, considers radiation and convection
default.discon boundary condition for the transport in the DISAMATIC® process (tem-
perature dependent heat transfer coefficient)
default.disdru boundary for the casting in the drum in the DISAMATIC® process, con-
siders radiation and convection
CH. 8: DATABASES 8-69

default.do boundary condition for die opening, considers radiation and convection
default.hpdc boundary condition for the HPDC process, considers radiation and con-
vection
default.lpdc boundary condition for the LPDC process, considers radiation and con-
vection (please refer also to Ch. 2.2.1, page 12 of the MAGMAlpdc 4.4
Manual for information on this dataset)
default.radiat boundary condition for the radiation of shells
default.shaout boundary condition for the casting after skakeout, considers radiation
and convection
default.spray boundary condition for spraying of the die (temperature dependent heat
transfer coefficient)
oven1* time dependent temperature profile as boundary condition for a heat
treatment process
quench* constant temperature as boundary condition for a quenching process
temper* time dependent march of temperature as boundary condition for a tem-
pering process
The datasets marked with * are designed for heat treatment processes only, e.g. the steel module
of MAGMASOFT®. They are not relevant for standard MAGMASOFT®.

Please refer also to the respective information under 'General Parameters' Î 'Short Description'.

In addition to the table above, the following table shows the use of the 'default' boundary condi-
tions in MAGMASOFT® depending on the different modules and options.
Boundary condi- Module/process Contact surfaces to Remarks
tion environment
default MAGMASOFT® (Stan- All materials except Condition is valid in
dard) feeder (material group batch production for all
12) material surfaces while
die is closed
default.12 MAGMASOFT® Contact surface feeder
(material group 12)
default.blow MAGMASOFT® (blow- All mold materials de-
ing / MAGMAspray) fined via 'spray defini-
tions'
8-70 MAGMASOFT® 4.4 MANUAL

default.coat MAGMASOFT® (coat- All mold materials All mold materials that
ing / MAGMAcoat) have contact with the
casting while die is
closed
default.cool MAGMASOFT® (cooling All channels that are not
channels) active
default.dc MAGMASOFT® (Stan- All materials after die Usually contact surfaces
dard, permanent molds) closing mold-casting
default.discas MAGMAdisa All cast alloy materials
and cores after shake
out
default.discon MAGMAdisa Mold materials that lie
on the conveyor belt
default.disdru MAGMAdisa All cast alloy materials Cooling in the cooling
after shake out drum
default.do MAGMASOFT® (Stan- All materials after die Usually contact surfaces
dard, permanent molds) opening mold-casting and mold-
mold
default.hpdc MAGMAhpdc All materials Valid for complete cycle
default.lpdc MAGMAlpdc All materials Valid for complete cycle
®
default.radiat MAGMASOFT (radia- All materials
tion / MAGMAradiation)
default.shaout MAGMASOFT® (shake All materials after shake
out / MAGMAshakeout) out
default.spray MAGMASOFT® (spray- All mold materials de-
ing / MAGMAspray) fined via 'spray defini-
tions'

8.4.2 Radiation and Convection / 'Radiation and Convection'

With this group of external boundaries the heat emission from the casting system to the environ-
ment is described by radiation (i.e. by emission of electromagnetic waves) and by convection (i.e.
by heat transfer caused by molecular activity).
CH. 8: DATABASES 8-71

List of Datasets in the 'MAGMA' Database

• default

• default.12

• default.dc

• default.discas

• default.disdru

• default.do

• default.hpdc

• default.lpdc

• default.radiat

• default.shaout

Please refer also to the respective information given in the list in Ch. 8.4.1, page 8-68.

Environment Temperature / 'Defaults'

In this window you enter the temperature of the casting system's environment. In most cases this
temperature is 20°C. However, you can define it at your choice, e.g. to consider special bound-
aries. If parts of the casting system are e.g. insulated from their environment (meaning that there
is a permanently higher temperature), you can define an individual thermal boundary with a higher
environment temperature for this area.

database
'Database' menu
Select Database
'Dataset' menu
'Boundary'
Group: 'Radiation and
Convection'
Select dataset
Edit
'Edit' menu
Fig. 8-29: Defining the environment temperature of external boundary 'Defaults'
conditions of the 'Radiation and Convection' type
8-72 MAGMASOFT® 4.4 MANUAL

Radiation Coefficient / 'Radiation'

In this window you specify the radiation coefficient ε depending on temperature. The higher the
coefficient is, the higher is the part of radiation to heat emission to the environment. The radiation
coefficient lies between 0 and 1, but these two limit values are never reached in the technical pro-
cess. A decrease of radiation, e.g. caused by melt coating, is described by a very small radiation
coefficient (e.g. 10-3), whereas you can consider a very strong radiation by coefficients of about
0.8 to 0.9.

database
'Database' menu
Select Database
'Dataset' menu
'Boundary'
Group: 'Radiation and
Convection'
Select dataset
Edit
'Edit' menu
'Radiation'

Fig. 8-30: Defining the radiation coefficient

The way to select, add, modify, delete or import values is the same as explained in the overview
on page 8-29. See this chapter for further information.
CH. 8: DATABASES 8-73

Heat Transfer Coefficient / 'Convection'

In this window you specify how much convection contributes to the heat transfer between the cast-
ing system and its environment. You can do this by defining the corresponding heat transfer co-
efficient as a function of temperature. The bigger this heat transfer coefficient is, the more
convection contributes to the heat transfer.

database
'Database' menu
Select database
'Dataset' menu
'Boundary'
Group: 'Radiation and
Convection'
Select dataset
Edit
'Edit' menu
'Convection'

Fig. 8-31: Defining the heat transfer coefficients of the 'Radiation and
Convection' type

The way to select, add, modify, delete or import values is the same as explained in the overview
on page 8-29. See this chapter for further information.
8-74 MAGMASOFT® 4.4 MANUAL

Effective HTC / 'Effective HTC (view only)'

The calculation of the effective temperature-dependent heat transfer coefficient is based on the
values for the environment temperature (TU), the radiation coefficient and the heat transfer coef-
ficient. The window (Fig. 8-32) serves for controling the edited heat transfer. You can thus only
view these values, but not edit them.

The calculation is possible only if you have defined all values. This function is only active if this is
the case accordingly.

database
'Database' menu
Select database
'Dataset' menu
'Boundary'
Group: 'Radiation and
Convection'
Select dataset
Edit
'Edit' menu
'Effective HTC (view
only)'

Fig. 8-32: Viewing the effective heat transfer coefficient

8.4.3 Heat Transfer Coefficient / 'HTC'

With this group of external boundaries, the heat transfer between the casting system and its en-
vironment is described by a defined heat transfer coefficient. You can access this group e.g. if you
CH. 8: DATABASES 8-75

alter the heat transfer from the "outside" (example: forced cooling by spraying) and if you are able
to set a defined heat transfer coefficient for such a process.

Datasets in the 'MAGMA' Database

• default.blow

• default.coat

• default.cool

• default.discon

• default.spray

Please refer also to the respective information given in the list in Ch. 8.4.1, page 8-68.

Environment Temperature / 'Defaults'

Here you define again, as described for 'Radiation and Convection' (Î page 8-71), the environ-
ment temperature of the casting system, which is 20°C in most cases. You can also choose an-
other value, depending on the existing process conditions.

database
'Database' menu
Select Database
'Dataset' menu
'Boundary'
Group: 'HTC'
Select dataset
Edit
'Edit' menu
'Defaults'
Fig. 8-33: Defining the environment temperature for external boundary
conditions
8-76 MAGMASOFT® 4.4 MANUAL

Heat Transfer Coefficient as a Function of Temperature / 'HTC'

In this window you define the heat transfer coefficient as a function of temperature. The height and
the course of the heat transfer coefficient depend on the process, for which the special boundaries
exist.

database
'Database' menu
Select database
'Dataset' menu
'Boundary'
Group: 'HTC'
Select dataset
Edit
'Edit' menu
'HTC'

Fig. 8-34: Defining heat transfer coefficients as a function of tempera-

ture

The way to select, add, modify, delete or import values is the same as explained in the overview
on page 8-29. See this chapter for further information.
CH. 8: DATABASES 8-77

8.5 Filter Data / 'Filter'

You must use the material group 'Filter' for volumes representing a filter within the casting system.
During the filling simulation, the pressure loss due to this filter is taken into account. During solid-
ification simulation volumes defined as filters have the same properties as the material defined for
the material group 'Cast Alloy'.

8.5.1 Filter Datasets in the 'MAGMA' Database

CEFILPB_4+2.7 CeramicFoam_40ppi FC-108-10

FC-108-13 FC-109-10 FC-116-10
FC-116-13 FC-121-15 FC-125-15
FC-125-22 FC-130-13 FC-132-10
FC-132-13 FC-133-10 FC-133-13
FC-135-11 FC-155-13 FC-155-22
FC-156-10 FC-156-13 FC-156-15
FC-156-18 FC-156-22 FC-157-13
FC-157-22 FC-166 FC-169-10
FC-169-13 FC-174 FC-175-10
FC-175-13 FC-175-15 FC-179-11
FC-180 FC-182-15 FC-183-18
FC-192-18 FC-193-22 FC-194
FC-196-18 FC-201-18 FC-208-13
FC-209-10 FC-209-13 FC-210-22
FC-211-13 FC-214-13 FC-224-15
FC-224-22 FC-236-13 FC-236-22
FC-242-13 FC-242-22 FC-246
FC-259-13 FC-266-13 FC-266-19
FC-281-22 FC-313-22 FC-316-13
FC-321-22 FC-454-19 FC-49.81
Foam_10ppi Foam_15ppi Foam_25ppi
Foam10ppi_heavy Foam10ppi_light Foam10ppi_medium
Foam20ppi_heavy Foam20ppi_light Foam20ppi_medium
8-78 MAGMASOFT® 4.4 MANUAL

Foam30ppi_heavy Foam30ppi_light Foam30ppi_medium

Sieve_0.55
If a filter dataset, whose name begins with "FC", has a two-digit final number that is separated with
a hyphen from the rest of the name, this final number indicates the filter's thickness in mm. The
filter of the dataset FC-211-13 e.g. has a thickness of 13 mm. The numbers given in ppi indicate
the porosity of the respective filter (ppi = pores per inch). The two datasets 'CEFILPB_4+2.7' and
'CeramicFoam_40ppi' stand for ceramic filters.

Please refer also to the respective information under 'General Parameters' Î 'Short Description'.

8.5.2 'Filter Parameters'

The following equation describes the pressure loss caused by a filter:

2
∆p = K 1 ⋅ v + K 2 ⋅ v Equation 8-10

∆p Pressure loss by the filter [Pa]

v Velocity of the melt

K1 Coefficient [kg/(m2s)]

K2 Coefficient [kg/(m3)]

The K1 and K2 coefficients account for laminar and turbulent pressure loss, respectively. You can
define them by experiment or by theory.

The K1 coefficient is related directly to the Darcy permeability coefficient by the following equation:

⋅η
K1 = L
----------- Equation 8-11
KD

K1 Darcy's specific permeability

L Length of the filter path (thickness) [m]

η Dynamic viscosity [kg/(ms)] a

CH. 8: DATABASES 8-79

KD Constant for structural properties

a. Dynamic viscosity is also defined as Pa ⋅ s.

You must distinguish two flow directions for the filter. The first direction is the main flow direction
through the filter. The second direction is the cross flow direction. By this you can consider an
anisotropy of the filter material. A sample filter configuration is shown in Fig. 8-35:

Fig. 8-35: Flow directions within a filter

An extruded filter e.g. consists of many channels that run parallel to the main flow direction. So no
cross flow exists for an extruded filter. You must set the coefficients for the cross flow to high val-
ues (e.g. 100.000) accordingly, in order to suppress the simulation of a cross flow direction.

Foam filters, on the other hand, allow all flow directions. The filter has isotropic properties. K1 und
K2 are identical in main and cross flow direction.
8-80 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'Filter'
Select dataset
Edit
'Edit' menu
'Filter Parameters'

Fig. 8-36: Defining filter parameters

If the two K1 and K2 coefficients for the pressure loss calculation are known already, you can input
them into the database you want. If they are unknown, MAGMASOFT® offers you the option to
define them automatically from measured pressure loss values. Proceed as follows (Fig. 8-36):

Ö Enter the pressure loss in main flow direction into the database ('Pressure Loss in s-Direction',
Î page 8-83)

Ö If required, enter the pressure loss in transverse flow direction into the database ('Pressure
Loss in t-Direction', Î page 8-84)

Ö Choose the function 'Calculate Coefficients from Pressure Loss Curves in s-Direction' in the
filter window in order to calculate the coefficients in main flow direction.

Ö Choose the function 'Calculate Coefficients from Pressure Loss Curves in t-Direction' in the
filter window in order to calculate the coefficients in cross flow direction.
CH. 8: DATABASES 8-81

Ö The program now calculates the coefficients K1 and K2. This is done using a least squares
approximation method (SVD Singular Value Decomposition).

For measuring the pressure loss data, water or air are often used. Measurings performed with
these materials are technically more sensible than those performed with the liquid metal used for
the mold filling simulation.

You should know the density of the fluid with which filter pressure loss measuring was performed.
You can enter the value of this density into the field 'density of reference material' of the 'Filter
Parameters' window (Fig. 8-36). Default is 1000 kg/m3. In most cases, such measuring is done
with water as a medium. Therefore MAGMASOFT® assumes the "default" reference fluid to be
water. This default is used if the user has not specified the density of the reference fluid as de-
scribed above.

Please refer also to page 5-27 pp of this manual ('filter definitions'). There you find information
about the definition of filters for the simulation of mold filling.

During geometry modeling you should mark each filter with a separate number ('MAT ID'). By
this you can control each filter individually (activate / deactivate). Please note that volumes that
you define as 'Filter' have the same material properties as the material assigned to 'Cast Alloy'.

In order to activate or deactivate a filter, use the 'active' function in the 'filter definitions' window
(sub-window of the 'filling definitions' window, Î page 5-27 pp of this manual). You do not need
to completely remove filters in the geometry modeling. Deactivated filters do neither influence the
filling nor the solidification simulation.

Filters are divided into following groups in the database (Fig. 8-37):

• 'Foam' (Î Ch. 8.5.3, page 8-86)

• 'Extruded'

• 'Sieve' (Î Ch. 8.5.4, page 8-87)

• 'Flow-Rite' (Î Ch. 8.5.5, page 8-89)

8-82 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'Filter'
Select dataset
Edit
'Edit' menu
'Global Information'

Fig. 8-37: Defining filters

CH. 8: DATABASES 8-83

Pressure Loss in Main Flow Direction / 'Pressure loss in s-Direction'

database
'Database' menu
Select database
'Dataset' menu
'Filter'
Select dataset
Edit
'Edit' menu
'Measured Pressure-
Loss Curve in s-Direc-
tion'

Fig. 8-38: Defining the pressure loss in main flow direction

Use this window (Fig. 8-38) to define the pressure loss in the main flow ('s') direction:

The values on the left define the pressure loss (value pairs velocity / pressure loss). The corre-
sponding graph is shown on the right side. The way to select, add, modify, delete or import values
is the same as explained in the overview on page 8-29. See this chapter for further information.

In order to compare the defined values with the approximation curve for the pressure loss, choose
'Approximated Pressure-Loss Curve in s-Direction' (Fig. 8-39). A diagram appears that displays
the values as dots as well as the approximated pressure loss curve.
8-84 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'Filter'
Select dataset
Edit
'Edit' menu
Approximated Pres-
sure-Loss Curve in s-
Direction'

Fig. 8-39: Displaying the approximated pressure loss in main flow direc-
tion

! Take care to input pressure losses in case of velocities v > 0,01 cm/s. In case of smaller
velocities the approximation process for the coefficients works less accurately.

Pressure Loss in Cross Flow Direction / 'Pressure loss in t-Direction'

Use this window (Fig. 8-40) to define the pressure loss in the cross flow ('t') direction:
CH. 8: DATABASES 8-85

database
'Database' menu
Select database
'Dataset' menu
'Filter'
Select filter
Edit
'Edit' menu
'Measured Pressure
Loss Curve in t-Direc-
tion

Fig. 8-40: Defining the pressure loss in cross flow direction

The values on the left define the pressure loss (value pairs velocity / pressure loss). The corre-
sponding graph is shown on the right side. The way to select, add, modify, delete or import values
is the same as explained in the overview on page 8-29. See this chapter for further information.

In order to compare the defined values with the approximation curve for the pressure loss, choose
'Approximated Pressure-Loss Curve in t-Direction'. A diagram appears that displays the values as
points as well as the approximated pressure loss curve.

! Take care to input pressure losses in case of velocities v > 0,01 cm/s. In case of smaller
velocities the approximation process for the coefficients works less accurately.
8-86 MAGMASOFT® 4.4 MANUAL

8.5.3 Foam Filters / 'Foam'

Foam Filter Datasets in the 'MAGMA' Database

CEFILPB_4+2.7 CeramicFoam_40ppi Foam_10ppi

Foam_15ppi Foam_25ppi Foam10ppi_heavy
Foam10ppi_light Foam10ppi_medium Foam20ppi_heavy
Foam20ppi_light Foam20ppi_medium Foam30ppi_heavy
Foam30ppi_light Foam30ppi_medium

! Some of these datasets are protected by a password.

Foam filters behave isotropic. This means that the pressure loss does not depend on the direction
of the flow. Both the pressure loss curves and the respective K1 and K2 coefficients of the main
and cross flow directions should be equal:

K1,s = K1,t

K2,s = K2,t
CH. 8: DATABASES 8-87

database
'Database' menu
Select database
'Dataset' menu
'Filter'
Group: Foam
Select dataset
Edit
'Edit' menu
'Filter Parameters'

Fig. 8-41: Defining parameters for foam filters

You can either enter the wanted coefficient directly or calculate the coefficient from the pressure
loss curve that you have entered (Fig. 8-41).

8.5.4 Sieve Filters / 'Sieve'

Sieve filters are normally very thin. Creating such a filter in the preprocessor would cause the
mesh generation to generate some very thin elements. This could significantly slow down the sim-
ulation. When modeling sieve filters you should therefore "artificially" enlarge their thickness in or-
der to generate a mesh that is not too fine.

The "reasonable" thickness is very much case dependent. On the one hand, you should not devi-
ate too much from the real thickness of the filter. On the other hand, specification of the filter object
should not have any negative influences on the mesh generation. If the mesh elements have a
8-88 MAGMASOFT® 4.4 MANUAL

thickness of 0.5 cm (in the filter's flow direction), you should define the filter in the preprocessor
with a thickness of 0.5 to 1 cm. In this case the filter will be generated with one or two mesh ele-
ments within. You should specify all the pressure loss constants (Ki) in the database as for a real
filter. You should define the filter length as in the preprocessor (i.e. relatively small pressure loss).
For example, if a sieve filter's thickness is 2 mm, and the filter defined in the preprocessor has the
thickness of 10 mm, you should define the filter length with a value of 10 mm.

This manipulation of the filter parameters enables you to calculate a modified pressure gradient
that leads to the same result as with the real filter (although the thickness has been changed). See
Ch. 8.5.2, page 8-78 for further information.
CH. 8: DATABASES 8-89

8.5.5 Flow-Rite Pressed Filters / 'Flow-Rite'

Pressed (Flow-Rite) Filter Datasets in the 'MAGMA' Database

FC-108-10 FC-108-13 FC-109-10

FC-116-10 FC-116-13 FC-121-15
FC-125-15 FC-125-22 FC-130-13
FC-132-10 FC-132-13 FC-133-10
FC-133-13 FC-135-11 FC-155-13
FC-155-22 FC-156-10 FC-156-13
FC-156-15 FC-156-18 FC-156-22
FC-157-13 FC-157-22 FC-166
FC-169-10 FC-169-13 FC-174
FC-175-10 FC-175-13 FC-175-15
FC-179-11 FC-180 FC-182-15
FC-183-18 FC-192-18 FC-193-22
FC-194 FC-196-18 FC-201-18
FC-208-13 FC-209-10 FC-209-13
FC-210-22 FC-211-13 FC-214-13
FC-224-15 FC-224-22 FC-236-13
FC-236-22 FC-242-13 FC-242-22
FC-246 FC-259-13 FC-266-13
FC-266-19 FC-281-22 FC-313-22
FC-316-13 FC-321-22 FC-454-19
FC-49.81

! These datasets are protected by a password.

Extruded filters only allow flow in the main direction. Cross flow is not possible. You should set
cross flow pressure loss coefficients to some high value accordingly, for example 100.000. You
do not have to define a pressure loss curve for this direction:

K1,t = 100000.0

K2,t = 100000.0
8-90 MAGMASOFT® 4.4 MANUAL

The K1,s and K2,s coefficients describe the pressure loss in the main flow direction. See Ch. 8.5.2,
page 8-78 for further information.

8.6 Geometry Data / 'Geometry'

You can administrate geometry data from the geometry modeling. Geometry data are divided into
the following groups:

• 'Formbox'

• 'Gating'

• 'Feeder'

• 'Other'

! Please refer also to Ch. 3.4, page 3-24 and Ch. 3.11.6, page 3-113 of this manual,
where the use of geometry data in the preprocessor is explained.

! The feeder geometries listed in Ch. 8.6.1, page 8-90 are mainly designed for European
countries. The geometric dimensions of the feeders are indicated in millimeters (mm).
This is of interest for working with the preprocessor.

8.6.1 Feeder Geometry Datasets in the 'MAGMA' Database

Kalmin70_1 Kalmin70_10 Kalmin70_11

Kalmin70_12 Kalmin70_13 Kalmin70_14
Kalmin70_15 Kalmin70_2 Kalmin70_3
Kalmin70_4 Kalmin70_5 Kalmin70_6
Kalmin70_7 Kalmin70_8 Kalmin70_9
KalminS_KSP10-13K KalminS_KSP12-15K KalminS_KSP3.5-5K
KalminS_KSP3.5-5KE KalminS_KSP4-5K KalminS_KSP4-7K
KalminS_KSP4-7KE KalminS_KSP4-95K KalminS_KSP5-8K
KalminS_KSP6-12K KalminS_KSP6-9K KalminS_KSP7-10K
KalminS_KSP8-11K KalminS_KSP9-12K

All these datasets are stored as CMD and GEO files. Please refer also to the respective informa-
tion under 'General Parameters' Î 'Short Description'.
CH. 8: DATABASES 8-91

8.6.2 View Geometry / 'Geometry (view only)'

With the function 'Geometry (view only)' from the menu 'Edit' you can view the geometry belonging
to a dataset (Fig. 8-42). You cannot modify the geometry in this window. Please modify the geom-
etry in the preprocessor before linking it to a database.

database
'Database' menu
Select database
'Dataset' menu
'Geometry'
Select dataset
Edit
'Edit' menu
'Geometry (view only)'

Fig. 8-42: Geometry display

8.6.3 Command Files / 'Cmd-File'

With the function 'Cmd-File' from the menu 'Edit' you can view and modify the CMD file belonging
to a dataset (Fig. 8-43). With 'Save' you save the changes made. Please note that these changes
8-92 MAGMASOFT® 4.4 MANUAL

will be saved automatically when you leave the window. Use 'Re-Load' to delete all changes and
to load the CMD file in its original form. Please refer also to Ch. 3.11.3, page 3-106 of this manual
('EDIT CMD').

database
'Database' menu
Select database
'Dataset' menu
'Geometry'
Select dataset
Edit
'Edit' menu
'Cmd-File'

Fig. 8-43: Invoking a command file

8.6.4 Import Geometry as GEO File / 'Import Geometry'

If you often use the same geometry elements, you should store these elements in the database.
You can import GEO files as well as CMD files (Î Ch. 8.6.5, page 8-95) into the database.

Proceed as follows to integrate GEO files into the database:

Ö Open the 'Data' menu and choose 'Import Geometry'. The window for selecting the wanted
file appears (Fig. 8-44).
CH. 8: DATABASES 8-93

database
'Database' menu
Select database
'Dataset' menu
'Geometry'
Select dataset
Edit
'Data' menu
'Import Geometry'
Select directory
Mark entry in 'Choice' list
('Import')

Fig. 8-44: Importing geometry files

Ö If the geometry file to be imported is stored in the directory of the current project version, you
can select the wanted geometry directly from the 'Choice' list. (The button 'Project
<name><current version>' next to 'Source' is active by default. In this case you are in this di-
rectory.)

Ö If the geometry file is stored in a different directory, choose the button 'Other' first to define the
directory of the file. You can then type in the directory's name into the field below 'Directory'
or select it using the button 'Select'. In the latter case the following window appears:
8-94 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'Geometry'
Select dataset
Edit
'Data' menu
'Import Geometry'
'Other'
'Select'
Select directory (and
confirm with 'OK')

Fig. 8-45: Selecting directory for importing geometry files

Ö Change to the directory in which the desired file is stored via mouse click in the list. With [..]
you change to the next higher directory. (Directories are shown in square brackets in the list.)

If you choose 'Directories', you can change to your home directory ('Home', only on UNIX), to
the directory of the current project version ('Current Project') or, via a selection window, to a
directory of your choice ('Other Projects'; please refer also to the description of 'Import From
Other Project' on page 8-19).

The chosen directory is shown above the list next to 'Directory'.

Ö Leave the window with 'OK' to return to the import window.

Ö After having selected the wanted directory there, the GEO files appear now in the 'Choice' list.
Mark the file that you want. It now appears in the field below 'Selected'.

Ö Start the import of the geometry file using the button 'Import'. With 'Cancel' you leave the win-
dow without changes.
CH. 8: DATABASES 8-95

8.6.5 Import Geometry as Command File / 'Import Cmd–File'

Proceed as follows to import a CMD file into the database:

Ö Choose 'Import Cmd-File' from the menu 'Data'. A window for the selection of the CMD file
appears (Fig. 8-46).

database
'Database' menu
Select database
'Dataset' menu
'Geometry'
Select dataset
Edit
'Data' menu
'Import Cmd-File'
Select directory
Mark entry in 'Choice' list
('Import')

Fig. 8-46: Importing command files

Ö If the command file to be imported is stored in the directory of the current project version, you
can select the wanted geometry directly from the 'Choice' list. (The button 'Project
<name><current version>' next to 'Source' is active by default. In this case you are in this di-
rectory.)

Ö If the command file is stored in a different directory, choose the button 'Other' first to define
the directory of the file. You can then type in the directory's name into the field below 'Direc-
tory' or select it using the button 'Select'. In the latter case the following window appears:
8-96 MAGMASOFT® 4.4 MANUAL

database
'Database' menu
Select database
'Dataset' menu
'Geometry'
Select dataset
Edit
'Data' menu
'Import Cmd-File'
'Other'
'Select'
Select directory (and
confirm with 'OK')

Fig. 8-47: Selecting directory for importing command files

Ö Change to the directory in which the desired file is stored via mouse click in the list. With [..]
you change to the next higher directory. (Directories are shown in square brackets in the list.)

If you choose 'Directories', you can change to your home directory ('Home', only on UNIX), to
the directory of the current project version ('Current Project') or, via a selection window, to a
directory of your choice ('Other Projects'; please refer also to the description of 'Import From
Other Project' on page 8-19).

The chosen directory is shown above the list next to 'Directory'.

Ö Leave the window with 'OK' to return to the import window.

Ö After having selected the wanted directory there, the command files appear now in the
'Choice' list. Mark the file that you want. It now appears in the field below 'Selected'.

Ö Start the import of the command file using the button 'Import'. With 'Cancel' you leave the win-
dow without changes.
CH. 8: DATABASES 8-97

8.7 Microstructure Data / 'Real Reality Realizer'

A dataset has been stored in the 'MAGMA' database that allows you to display microstructure pic-
tures of the alloy AlSi7Mg in the postprocessor. Please find this dataset called 'default.das' at
'Dataset' Î 'Real Reality Realizer'.

If you want to create your own datasets for microstructure pictures of different alloys, then please
proceed as described in the following. Note the following:

• The postprocessor always selects the dataset called 'default.das' when you activate the 'Real
Reality Realizer' function. If you want to create user-defined microstructure pictures for a dif-
ferent alloy, then you have to give the name 'default.das' to the dataset for the alloy you want
to display and to save it in one of the databases 'Project' or 'User'.

Of course you can create as many datasets as you like using different names, but you need
to rename and to save the desired dataset as described above before you start the display in
the postprocessor. Please take care not to have more than one dataset called 'default.das' in
the entire database.

• If you want to save your own pictures, their file format must be JPG.
8-98 MAGMASOFT® 4.4 MANUAL

8.7.1 Defining Dendrite Arm Spacings / 'Samples'

database
'Database' menu
Select 'Project' or 'User' database
'Dataset' menu
'Real Reality Realizer'
Select 'default_das' dataset
'Edit'
'Edit' menu
'Samples'

Fig. 8-48: Defining dendrite arm spacings

Using the 'Samples' function from the 'Edit' menu, you can define the dendrite arm spacings
('DAS') in µm for the display of microstructure pictures. You must assign a JPG image to each val-
ue. Fig. 8-48 shows the dendrite arm spacings for the default dataset 'default.das' (AlSi7Mg alloy).
Proceed as follows to define new data:
'New' Using the 'New' command, you can define a new value for the dendrite arm
spacings (Fig. 8-49).
CH. 8: DATABASES 8-99

'Delete' The 'Delete' command allows you to delete the currently marked value. If you
select values while pressing the SHIFT key, you can mark several values at
the same time. If you press the SHIFT and the CTRL key during selection, you
can select all values at the same time.
'Display' The microstructure picture of the marked value is displayed. Choose 'dismiss'
to quit the picture.

database
'Database' menu
select 'Project' or 'User'
database
'Dataset' menu
'Real Reality Realizer'
select 'default_das'
dataset
'Edit'
'Edit' menu
'Samples'
'New'

Fig. 8-49: Defining properties of dendrite arm spacings

Please proceed as follows to create your own data for microstructure pictures:

Ö First create the microstructure pictures in the JPG format and save them in a directory of your
choice.

Ö Select 'New' from the 'Samples' menu. A window appears allowing you to define dendrite arm
spacings and to assign pictures to these spacings (Fig. 8-49).

Ö Enter dendrite arm spacing in µm at 'DAS'.

8-100 MAGMASOFT® 4.4 MANUAL

Ö Assign a microstructure picture to this spacing, either by entering a path in the 'Directory' field
and confirming it with the Enter key or by selecting a directory via the 'Select' button. There-
upon all JPG image files contained in the selected directory appear in the 'Choice' field.

Ö Mark the image file you want to assign to the dendrite arm spacing in the 'Choice' list. There-
upon the file name also appears in the field under 'Selected', and the 'Create Sample' button
is activated.

Ö Select 'Create Sample' to start the assignment. A successful assignment is confirmed by the
message 'Sample created successfully!'.

Ö Repeat the last four steps for all dendrite arm spacings to which you want to assign pictures.

Ö Choose 'Cancel' to quit the window and to return to the 'Samples' window. (If you choose 'Can-
cel' before the program has successfully completed an assignment, then your input for this
step is not saved.)

! You do not have to quit and to re-invoke the window each time to assign pictures to sev-
eral dendrite arm spacings. After the confirmation has appeared, you can directly enter
a new value at 'DAS' and assign another picture as described above. After you have ter-
minated your definitions, all values are displayed in the 'Samples' window.

! When you activate the 'Real Reality Realizer' function in the postprocessor, the program
searches for the microstructure picture that is closest to the currently calculated micro-
structure concerning the dendrite arm spacing at this point.

8.7.2 Defining Alloy Constant / 'Alloy Constant'

database
'Database' menu
select 'Project' or 'User'
database
'Dataset' menu
'Real Reality Realizer'
select 'default_das'
dataset
'Edit'
'Edit' menu
Fig. 8-50: Defining alloy constants 'Alloy Constant'
CH. 8: DATABASES 8-101

Using the 'Alloy Constant' function (Fig. 8-50), you can define the alloy constant for the dataset
'default.das', which is important for the relation between the dendrite arm spacing and the local
solidification time. The unit is micrometers per a third of a second.

8.8 Table of Figures

Fig. 8-1: The main window of the MAGMASOFT® databases................................................... 8-8

Fig. 8-2: Assigning information to data .................................................................................... 8-14
Fig. 8-3: Entering a memo ....................................................................................................... 8-17
Fig. 8-4: Importing datasets into a different database.............................................................. 8-18
Fig. 8-5: Importing data from Release 2 .................................................................................. 8-20
Fig. 8-6: Searching directory for data from Release 2 ............................................................. 8-21
Fig. 8-7: Converting project files .............................................................................................. 8-24
Fig. 8-8: Defining general material parameters........................................................................ 8-26
Fig. 8-9: Defining the thermal conductivity of a material .......................................................... 8-29
Fig. 8-10: Importing values from files....................................................................................... 8-31
Fig. 8-11: Defining the density of a material ............................................................................ 8-32
Fig. 8-12: Defining the specific heat capacity of a material...................................................... 8-33
Fig. 8-13: Defining the solidification interval of a material........................................................ 8-34
Fig. 8-14: Display of the specific heat content of a material .................................................... 8-35
Fig. 8-15: Defining the flow properties of a material ................................................................ 8-36
Fig. 8-16: Defining the Newtonian viscosity of a material ........................................................ 8-38
Fig. 8-17: Defining the erosion parameters of a material......................................................... 8-39
Fig. 8-18: Defining material composition.................................................................................. 8-40
Fig. 8-19: Defining the exothermic properties of a material ..................................................... 8-41
Fig. 8-20: Overview of internal heat transfer coefficients......................................................... 8-50
Fig. 8-21: Defining a constant heat transfer coefficient............................................................ 8-57
Fig. 8-22: Increasing heat transfer coefficient with rising temperature .................................... 8-59
Fig. 8-23: Defining temperature dependent heat transfer coefficients ..................................... 8-60
Fig. 8-24: Defining time dependent heat transfer coefficients.................................................. 8-61
8-102 MAGMASOFT® 4.4 MANUAL

Fig. 8-25: Defining the coating thickness ................................................................................. 8-62

Fig. 8-26: Importing material properties for coatings ............................................................... 8-63
Fig. 8-27: Defining the parameters for cooling channel heat transfers .................................... 8-65
Fig. 8-28: Importing material properties for cooling channels .................................................. 8-66
Fig. 8-29: Defining the environment temperature of external boundary conditions of the 'Radiation
and Convection' type ............................................................................................. 8-71
Fig. 8-30: Defining the radiation coefficient.............................................................................. 8-72
Fig. 8-31: Defining the heat transfer coefficients of the 'Radiation and Convection' type ........ 8-73
Fig. 8-32: Viewing the effective heat transfer coefficient ......................................................... 8-74
Fig. 8-33: Defining the environment temperature for external boundary conditions ................ 8-75
Fig. 8-34: Defining heat transfer coefficients as a function of temperature.............................. 8-76
Fig. 8-35: Flow directions within a filter.................................................................................... 8-79
Fig. 8-36: Defining filter parameters......................................................................................... 8-80
Fig. 8-37: Defining filters .......................................................................................................... 8-82
Fig. 8-38: Defining the pressure loss in main flow direction..................................................... 8-83
Fig. 8-39: Displaying the approximated pressure loss in main flow direction .......................... 8-84
Fig. 8-40: Defining the pressure loss in cross flow direction.................................................... 8-85
Fig. 8-41: Defining parameters for foam filters......................................................................... 8-87
Fig. 8-42: Geometry display..................................................................................................... 8-91
Fig. 8-43: Invoking a command file .......................................................................................... 8-92
Fig. 8-44: Importing geometry files .......................................................................................... 8-93
Fig. 8-45: Selecting directory for importing geometry files....................................................... 8-94
Fig. 8-46: Importing command files.......................................................................................... 8-95
Fig. 8-47: Selecting directory for importing command files ...................................................... 8-96
Fig. 8-48: Defining dendrite arm spacings ............................................................................... 8-98
Fig. 8-49: Defining properties of dendrite arm spacings .......................................................... 8-99
Fig. 8-50: Defining alloy constants......................................................................................... 8-100
CH. 8: DATABASES 8-103

Notes
8-104 MAGMASOFT® 4.4 MANUAL

Notes
CH. 8: DATABASES 8-105

Notes
8-106 MAGMASOFT® 4.4 MANUAL

Notes