Numerical optimisation of investment-cast wheel components for drone applications using MAGMASOFT®

Abstract

Investment casting technology of thin-walled components for drone applications requires precise filling and solidification control to minimise porosity and ensure structural integrity. Porosity is one of the most common defects found in castings, and its prediction and analysis are essential for improving the quality of complex superalloy components. In this work, porosity-related defects were examined using the MAGMASOFT® 6.1 numerical simulation software for casting, focusing on the filling and solidification behaviour of an investment casting wheel body component in drone applications. A series of simulations were performed, and two design and simulation versions were developed, analysed and compared. The wheel body component selected for this work is made of IN713 superalloy. The numerical modelling included the assessment of porosity distribution, hot spot formation, filling behaviour, cooling, and solidification patterns. Fifteen combinations of alloy and shell initial temperatures were evaluated to determine the most favourable thermal conditions for reducing porosity, considering the specific geometry and casting characteristics of the wheel. Based on the initial results, the casting design was modified by adjusting the runner geometry and assembly configuration. This study introduces a two-stage simulation approach to optimise porosity reduction. The second version of the simulations demonstrated a noticeable reduction in pores, particularly in critical regions of the wheel body. The findings can support drone component manufacturers in improving casting reliability. The results confirm that simulation-driven optimisation of the casting design and thermal parameters can significantly improve the quality of the components produced by investment casting technology.