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There are several universities doing the same. Even smaller universities such as Wright State University in Dayton Oh. that is working on flow modeling programs for both liquid and Semi Solid Casting that look quite promising. One thing though, you just can't see inside the die as the part is...

arunmrao, I reckon that's why casting is still part art form.

pparent, Specifying defect levels in castings is never easy with most instances involving some physical test such as leak testing or pressure testing. For example pump housing castings are pressure checked first at 100% until a level of comfort is obtained then dropped to some lower level...

I'm new to the forum and appreciate all of the experience and knowledge. It is difficult some times achieving defect free Al casting when using sand, perm. mold, or HPDC, however it is doable. A356 lends itself well to not only these processes but also squeeze and my favorite, semi solid...