𝗗𝘂𝗮𝗹-𝗪𝗶𝗿𝗲 𝗪𝗔𝗔𝗠 𝗦𝗶𝗺𝘂𝗹𝗮𝘁𝗶𝗼𝗻: 𝗔𝗹𝘂𝗺𝗶𝗻𝘂𝗺 𝗠𝗲𝗲𝘁𝘀 𝗦𝘁𝗮𝗶𝗻𝗹𝗲𝘀𝘀 𝗦𝘁𝗲𝗲𝗹 Here’s a glimpse of our latest Wire Arc Additive Manufacturing (WAAM) simulation using 𝐅𝐋𝐎𝐖-𝟑𝐃 𝐀𝐌 — featuring simultaneous deposition of AA6061 and stainless steel 316L wires on an AA6061 substrate. The model reveals melt pool dynamics, material mixing, and interface evolution between the two alloys. The video shows the volume fraction of 316L throughout deposition and the final bead geometry. This study deepens our understanding of multi-material interaction and process control in hybrid WAAM systems. El-Refay Engineering Services, we help manufacturers harness the power of simulation to revolutionize additive manufacturing. #Additive_Manufacturing #WAAM #FLOW3D #CFD #MetalAM #Simulation #316L #AA6061 #ElRefay #Advanced_Manufacturing

🔹 𝗩𝗶𝘀𝘂𝗮𝗹𝗶𝘇𝗶𝗻𝗴 𝘁𝗵𝗲 𝗦𝗮𝗻𝗱 𝗖𝗮𝘀𝘁𝗶𝗻𝗴 𝗼𝗳 𝗮𝗻 𝗔𝗹𝘂𝗺𝗶𝘂𝗺 𝗣𝘂𝗺𝗽 𝗛𝗼𝘂𝘀𝗶𝗻𝗴 In this simulation, the filling process of an AlSi10Mg pump housing is modeled using 𝗙𝗟𝗢𝗪-𝟯𝗗 𝗖𝗔𝗦𝗧, operating at a pouring temperature of 720°C and a filling velocity of 30 cm/s. This visualization demonstrates how CFD reveals the complex flow behavior during casting, offering deep insights into: 🌀 Filling pattern evolution throughout the mold cavity 🌡 Temperature distribution within the molten metal and mold ⚙ Pressure variations affecting flow stability 💨 Entrained air mass and air entrapment zones 💧 Free surface defect concentration, highlighting turbulence-related risks These insights from 𝗙𝗟𝗢𝗪-𝟯𝗗 𝗖𝗔𝗦𝗧 empower foundry engineers to optimize gating design, reduce casting defects, and enhance process reliability — long before pouring the first mold. #elrefay #flow3d #flow3dcast #CFD #simulation #casting #sandcasting #AlSi10Mg #foundry #metallurgy

The FLOW-3D 2025 Taiwan User Conference will take place November 4th in Taipei. Co-hosted by Flow Science and HyperInfo, the conference will feature presentations from FLOW-3D software users across hydraulics, casting, welding, and additive manufacturing, as well as updates on the latest developments in the FLOW-3D product family.  #flow3d #cfd #usersconference 

From rubber seals to plastic panels and glass parts, Ansys Polyflow simulates every stage of the manufacturing process - extrusion, thermoforming, blow molding, glass forming, and fiber spinning. It helps engineers predict material flow, thickness, and cooling behavior long before the first mold is made, saving time, cost, and waste. 💡 Now part of Ansys CFD Pro and Premium, giving more teams access to advanced polymer and glass flow simulation. Find out more about Ansys Polyflow in the latest 2025R2 release --> https://lnkd.in/dTVkiDgV #AnsysPolyflow #AnsysFluids #Simulation #ManufacturingI #Ansys2025R2 #CFD #EngineeringDesign

🔍 What happens when additive manufacturing meets CFD simulation? We put a gyroid lattice under the microscope - and the results were fascinating. From meshing challenges to flow insights, this study reveals how advanced geometry impacts real-world performance. How uniform is the flow? What happens to pressure drop as velocity climbs? Can gyroids really redefine heat exchanger design? Swipe through to find out. 👉 Read the full case study here: https://lnkd.in/dgkJBpK5 #CFD #Ansys #AdditiveManufacturing #HeatExchanger #GyroidLattice #EngineeringSimulation #3DDesign

At Metal Casting Development LLC, we recently helped a foundry redesign the casting process for a low volume V6 cylinder block — and the results speak for themselves: >Scrap reduced: from 100% → 1.2% >Weight reduced: by 16 kg per casting >Cost savings achieved through innovative use of lower cost in use supplementary feeding solutions. By combining solidification modeling, design by analysis, and practical foundry experience, we delivered a process that not only exceeded performance goals but also improved efficiency and sustainability. This is what happens when engineering, simulation, and manufacturing expertise come together with a focus on results. Let’s talk if you’re looking to improve yield, cut costs, or optimize your casting process. #MetalCasting #ManufacturingInnovation #CastingDesign #CFD #FoundryEngineering #ProcessOptimization

Exploring the invisible side of additive manufacturing 🔬 This ANSYS simulation shows residual stress behavior during the Wire Arc Additive Manufacturing (WAAM) process — a key factor that affects dimensional accuracy and structural performance. Each simulation step brings me closer to understanding how to make metal additive manufacturing more reliable and efficient. #Engineering #WAAM #ANSYS #AdditiveManufacturing #Simulation #Research

Every simulation begins long before the first spark ⚡ — it starts with the mesh. This finite element model represents the foundation of my thermo-mechanical simulation for Wire Arc Additive Manufacturing (WAAM). To capture the physics of heat flow, layer activation, and stress buildup, the model combines a 150×100×10 mm substrate with 25 stacked weld beads, each just 2 mm high — forming a 50 mm metallic wall built layer by layer, just like the real process itself. Over 31,000 elements and 45,000 nodes were carefully designed to balance precision and performance. Fine meshes near the molten zone ensure thermal accuracy, while coarser regions reduce computational load — a subtle equilibrium between physics and processing power. Using SOLID279 elements in ANSYS APDL, this thermal model serves as the first step toward predicting residual stress, distortion, and structural integrity in WAAM components. It’s fascinating how a simple grid of elements can simulate an entire manufacturing reality — where every node holds a story of heat, strain, and transformation. 🔥 #WAAM #AdditiveManufacturing #Simulation #ANSYS #ThermalModel #ResidualStress #FiniteElementAnalysis #Engineering #Research #Metallurgy

🌍 We continue to strengthen our global collaborations and project partnerships. In the field of additive manufacturing, particularly within cold spray technology, the demand for high-strength and lightweight materials used in aerospace applications — including component production, repair, and coating — is rapidly increasing. In this context, we are focusing on the development of next-generation 7xxx series aluminum alloys. Following the alloy design and validation studies, ultrasonic atomization will be employed through our international partners for powder production. Subsequently, cold spray nozzle design, process monitoring, and optimization studies will be carried out, leading to the final field testing phase. The growing interest from leading players in the civil aviation industry further strengthens our project and motivates our team toward excellence. 🤝 I would like to thank all our team members and project partners for their valuable contributions. Looking forward to achieving many more successful projects together. #AdditiveManufacturing #ColdSpray #AerospaceMaterials #AdvancedAlloys #UltrasonicAtomization #HighStrengthAluminum #7xxxSeries #MaterialsScience #Innovation #ResearchAndDevelopment #Collaboration #AerospaceEngineering #SustainableManufacturing #PowderMetallurgy #Teamwork

Streamlining Mold Development & Optimizing Mold Design with Simulation! In this article, the research team used Moldex3D to predict the temperature and flow field of conformal cooling system, which were validated through on-site testing. The high-cost beryllium copper mold was successfully replaced with a more cost-effective stainless steel mold. This not only reduced the environment impact but also doubled the mold's lifespan, while achieving a more mold temperature distribution. Read Full Article ⨠ https://reurl.cc/nYk1a2 #Moldex3D #mold #molding #injectionmolding #molddevelopment #molddesign #simulation #cooling